Etching Large Brass Sheets Is Harder Than You Think

One of my favorite ways to think of engineering is that a glass is not half empty or half full, only twice as large as it needs to be. As useful as that idea is, it also means that I rarely put any effort into the aesthetics of my projects – I learn or accomplish what I need, desolder and recycle the components, then move on. Few of my projects are permanent, and custom cases tend to be non-reusable, so I skip the effort and expense.

Once in a while though, I need to make a gift. In that case form and function both become priorities. Thankfully, all that glitters is not gold – and over the last year I’ve been learning to etch the copper alloys commonly classified as ‘brass’. We’ve covered some truly excellent etched brass pieces previously, and I was inspired to try and etch larger pieces of metal (A4 and larger) without sacrificing resolution. I thought this would be just like etching circuits. In fact, I went through several months of failed attempts before I produced anything halfway decent!

Although I’m still working on perfecting my techniques, I’ve learned enough in the meantime to give a report. Read on if you’re feeling the need for more fancy brass signs in your life.

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Writing A Message In Hypnotizing Style

If you’ve ever encountered a rapidly spinning split-flap displays at an airport terminal, it’s hard not to stop and marvel at them in action for a few extra seconds. Because of this same fascination, [M1k3y] began restoring an old one-hundred and twenty character sign, which he outlines the process of on his blog.

Finding documentation on this old relic turned out to be an impossibility; the producers of the model themselves didn’t even keep it off-hand any longer. In spite of that, [M1k3y] was able to determine the function of the small amount of circuitry driving the sign through process of elimination by studying the components. After nearly a year of poking at it, he happened across a video by the Trollhöhle Compute Club, demonstrating the successful use of the same display model. Luckily, they were kind enough to share their working source code. By reverse engineering the serial protocol in their example, he was able to write his own software to get the sign moving at last.

Once up and running, [M1k3y] learned that only eighty of the sign’s characters were still operable, but that is plenty to make a mesmerizing statement! Here is a video of the cycling letters in action:

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