Tool Hacks

2884 Articles

Better Laser Cuts: Know Your Kerf

April 15, 2023 by 19 Comments

The recent crop of laser cutters are nothing short of miraculous. For a few hundred dollars you can get a machine that can easily engrave and — subject to materials — cut well, too. [Nate] has been taking advantage of a laser to make boxes that join together using finger joinery. The problem is, the pieces have to fit exactly to get a good box. While setting dimensions in software is fine, you need to account for how much material the laser removes — something traditional woodworkers and machinists know as kerf.

You can, of course, employ trial and error to get good results. But that’s wasteful and potentially time-consuming. [Nate] built a “tolerance fence” that is quick to cut out and allows accurate measurement of kerf. You can quickly use the tolerance fence to make measurements and increase your chances of nailing your boxes on the first cut.

You have to customize the fence based on the thickness of your material. [Nate] uses Lightburn, which probably has a kerf offset already set by default in your layers. If not, you’ll need to turn it on and set an estimate of your kerf size. Then you are ready to cut the fence pieces and see how they fit together.

If the fit is too loose, you want to raise the kerf setting and try again. If it is too tight, you lower the kerf setting. As [Nate] says, “Lower equals looser.”

The results speak for themselves, as you can see in the treasure chest image [Nate] provided. Well worth the effort to get this parameter right. We do enjoy laser cutting and engraving things. If you are cutting and don’t have air assist, you really need to hack up something.

Kicad Autorouting Made Easy

April 14, 2023 by 23 Comments

One of the most laborious tasks in PCB layout is the routing. Autorouting isn’t always perfect, but it is nice to have the option, even if you only use it to get started and then hand-tune the resulting board. Unfortunately, recent versions of Kicad have dropped support for autorouting. You can, however, still use Freerouting and the video from [Mr. T] below shows you how to get started.

There are three ways to get the autorouting support. You can install Java and a plugin, you can isntall using a ZIP file, or you can simply export a Specctra DSN file and use Freerouting as a standalone program. Then you import the output DSN file, and you are done.

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Hackathon Wire EDM Build Really Works

April 13, 2023 by 12 Comments

If you’ve ever short-circuited a car battery, you’ve seen the pitting and damage a few sparks can cause. Smart minds realised that controlled sparks could erode metal very accurately, in a process now known as electrical discharge machining. [Tanner Beard] decided to build just such a machine for a hackathon, and it works a treat.

[Tanner]’s video explains the benefits of EDM well. Spark-based machining doesn’t care about the hardness of the given material, making it ideal for working with very tough steels, for example. It’s also non-contact, so the motion platform doesn’t have to be built to resist huge forces.

The build was done with a low budget of just $300, and uses some smart shortcuts. Instead of an expensive mains-powered DC power supply to generate the discharge, [Tanner] just uses a powerful lithium-polymer battery with his own MOSFET board to deliver the high current needed. A nifty combination of a stepper motor and O-drive motor setup feed the discharge wire at a constant rate during the machining.

Overall, it’s a neat build that shows wire EDM doesn’t have to break the bank. We’ve seen other similar builds before, too. Video after the break.

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Your Multimeter Might Be Lying To You

April 10, 2023 by 33 Comments

Multimeters are indispensable tools when working on electronics. It’s almost impossible to build any but the most basic of circuits without one to test and troubleshoot potential issues, and they make possible a large array of measurement capabilities that are not easily performed otherwise. But when things start getting a little more complex it’s important to know their limitations, specifically around what they will tell you about circuits designed for high frequency. [watersstanton] explains in this video while troubleshooting an antenna circuit for ham radio.

The issue that often confuses people new to radio or other high-frequency projects revolves around the continuity testing function found on most multimeters. While useful for testing wiring and making sure connections are solid, they typically only test using DC. When applying AC to the same circuits, inductors start to offer higher impedance and capacitors lower impedance, up to the point that they become open and short circuits respectively. The same happens to transformers, but can also most antennas which often look like short circuits to ground at DC but can offer just enough impedance at their designed frequency to efficiently resonate and send out radio waves.

This can give some confusing readings, such as when testing to make sure that a RF connector isn’t shorted out after soldering it to a coaxial cable for example. If an antenna is connected to the other side, it’s possible a meter will show a short at DC which might indicate a flaw in the soldering of the connector if the user isn’t mindful of this high-frequency impedance. We actually featured a unique antenna design recently that’s built entirely on a PCB that would show this DC short but behaves surprisingly well when sending out WiFi signals.

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Busting Wireless ESD Wrist Straps With LTT And ElectroBOOM

April 10, 2023 by 28 Comments

Nobody likes getting zapped from an electrostatic discharge, no matter whether you’re a fragile ASIC or a bag-of-mostly-salty-water humanoid. To prevent this, ESD wrist straps and similar are essential tools, as they prevent the build-up of a charge on your humanoid’s skin, essentially like a very large electrolyte-filled capacitor. Yet you can buy wireless ESD straps everywhere that are supposed to somehow dissipate this charge into the ether, even though this would seem to undermine the laws of physics that make capacitors work.

In a practical experimentation and assorted hijinks video collaboration by [Linus] from Linus Tech Tips and [Mehdi Sadaghdar] from ElectroBOOM put these wireless ESD straps to the test, featuring [Mehdi]’s DIY Van de Graaff generator to charge [Linus] up. What is excellently demonstrated in this video is how effective a real ESD strap is, and how the ‘wireless’ version is just a scam that does absolutely nothing to dissipate the charge, being just a waste of a 1 MOhm resistor and what could have been a real ESD strap.

Also covered in the video are what the reason for the resistor in an ESD strap is, and why metal bracelet type ESD straps are not appropriate, for very good reasons.

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A Soft Soldering Jig For Hard Projects

April 5, 2023 by 20 Comments

We’ve seen some absolutely gorgeous freeform circuit sculptures. There’s a mystic quality to taking what has normally been hidden away for safety and reliability reasons and putting it on display for everyone to see. Of course, creating these unique circuit sculptures takes considerable time and effort. [Inne] created several silicone soldering jigs to help with these tricky joints.

While a vice or helping hands is crucial for many joints, when dealing with tiny SMD components and exacting angles, you need something a little more specialized. Double-sided tape is often recommended, but heat ruins the adhesive and SMD components like to stick to soldering iron tips. Since silicone tends to be heat resistant, it makes a decent material for soldering on. [Inne] uses a city analogy with the cups for soldering called plazas, each with a hole (called a manhole) leading to a foot-switch vacuum pump to keep parts in place. The OpenSCAD code is available on GitHub under a GPLv3 license. It generates a two-part mold that you can cast in A-8/A-15 silicone.

It’s a clever project that makes it far easier to assemble gorgeous circuit sculptures. We love the design and thought that went into it, particularly the naming scheme as we often find appropriately naming variables in OpenSCAD quickly becomes difficult.

The BLE Datalogging Scale Of A Thousand Uses

March 29, 2023 by 7 Comments

Whether you’re making coffee or beer or complex chemicals, weighing your ingredients carefully and tracking them is key to getting good results. [Tech Dregs] decided to build a logging scale that would work seamlessly with his smartphone, and shared the design on YouTube.

The design begins with a Greater Goods manual electronic scale, which was chosen for its convenient design and 750 gram load cell. Once cracked open, [Tech Dregs] pulled out the original PCB to replace it with his own. Only the original buttons are used, with an Seed Xiao ESP32-C3 replacing the scale’s original brains. The original LCD screen was swapped out for an OLED display, and it also got a rechargeable lithium battery for better usability.

The real value of the project, though, is its communication capability. It’s able to talk to an Android smartphone over Bluetooth Low Energy. Thanks to a custom app, [Tech Dregs] is able to log weight readings from the scale over time and even graph them live on the smartphone. As a demonstration, the scale is used to log the weight of a cup as it fills with a shot of coffee, which should serve [Tech Dregs] well in his coffee automation projects.

We’ve seen bathroom scales hacked before, too, with similar connectivity upgrades.

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