Here at Hackaday, we thought we’d seen every method of making PCBs: CNC machining, masking and etching with a variety of chemicals, laser engraving, or even the crude but effective method of scratching away the copper with a utility knife. Whatever works is fine with us, really, but there still does seem to be room for improvement in the DIY PCB field. To whit, we present rapid PCB prototyping with electrical discharge machining.
Using an electric arc to selectively ablate the copper cladding on a PCB seems like a great idea. At least that’s how it seemed to [Jake Wachlin] when he realized that the old trick of cutting a sheet of aluminum foil using a nine-volt battery and a pencil lead is really just a form of EDM, and that the layer of copper on a PCB is not a million miles different from foil. A few experiments with a bench power supply and a mechanical pencil lead showed that it’s relatively easy to blast the copper from a blank board, so [Jake] took the next logical step and rigged up an old 3D-printer to move the tool. The video below shows the setup and some early tests; it’s not perfect by a long shot, but it has a lot of promise. If he can control the arc better, this homebrew EDM looks like it could very rapidly produce prototype boards.
[Jake] posted this project in its current state in the hopes of stimulating a discussion and further experimentation. That’s commendable, and we’d really love to see this one move along rapidly. You might start your brainstorming by looking at this somewhat sketchy mains-powered EDM, or look into the whole field in a little more detail.
Continue reading “Prototyping PCBs With Electrical Discharge Machining”
Remember when tricking out a bike with a headlight meant clamping a big, chrome, bullet-shaped light to your handlebar and bolting a small generator to your front fork? Turning on the headlight meant flipping the generator into contact with the front wheel, powering the incandescent bulb for the few feet it took for the drag thus introduced to grind you to a halt. This ridiculous arc-lamp bicycle headlight is not that. Not by a long shot.
We’re used to seeing [Alex] doing all manner of improbable, and sometimes impossible, things on his popular KREOSAN YouTube channel. And we’re also used to watching his videos in Russian, which detracts not a whit from the entertainment value for Andglophones; subtitles are provided for the unadventurous, however. The electrodes for his arc light are graphite brushes from an electric streetcar, while the battery is an incredibly sketchy-looking collection of 98 18650 lithium-ion cells. A scary rat’s nest of coiled cable acts as a ballast to mitigate the effects of shorting when the arc is struck. The reflector is an old satellite TV dish covered in foil tape with the electrodes sitting in a makeshift holder where the feedhorn used to be. It’s bright, it’s noisy, it’s dangerous, and it smokes like a fiend, but we love it.
Mounting it to the front of the bike was just for fun, of course, and it works despite the janky nature of the construction. The neighbors into whose apartments the light was projected could not be reached for comment, but we assume they were as amused as we were.
Continue reading “DIY Arc Light Makes An Unnecessarily Powerful Bicycle Headlight”
You may think electrochemistry sounds like an esoteric field where lab-coated scientists labor away over sophisticated instruments and publish papers that only other electrochemists could love. And you’d be right, but only partially, because electrochemistry touches almost everything in modern life. For proof of that look no further than your nearest pocket, assuming that’s where you keep your smartphone and the electrochemical cell that powers it.
Electrochemistry is the study of the electrical properties of chemical reactions and does indeed need sophisticated instrumentation. That doesn’t mean the instruments have to break the grant budget, though, as [Kyle Lopin] shows with this dead-simple potentiostat built with one chip and one capacitor. A potentiostat controls the voltage on an electrode in an electrochemical cell. Such cells have three electrodes — a working electrode, a reference electrode, and a counter electrode. The flow of electrons between these electrodes and through the solutions under study reveal important properties about the reduction and oxidation states of the reaction. Rather than connect his cell to an expensive potentiostat, [Kyle] used a Cypress programmable system-on-chip development board to do everything. All that’s needed is to plug the PSoC into a USB port for programming, connect the electrodes to GPIO pins, and optionally add a 100 nF capacitor to improve the onboard DAC’s accuracy. The video below covers the whole process, albeit with a barely audible voiceover.
Still not sure about electrochemistry? Check out this 2018 Hackaday Prize entry that uses the electrochemistry of life to bring cell phones back to life.
Continue reading “Cheap PSoC Enables Electrochemistry Research”
Microwave oven transformer spot welder builds are about as common as Nixie tube clocks around here. But this spot welder is anything but common, and it has some great lessons about manufacturing techniques and how to achieve a next level look.
Far warning that [Mark Presling] has devoted no fewer than five videos to this build. You can find a playlist on his YouTube channel, and every one of them is well worth the time. The videos covering the meat of what went into this thing of beauty are below. The guts are pretty much what you expect from a spot welder — rewound MOT and a pulse timer — but the real treat is the metalwork. All the very robust parts for the jaws of the welder were sand cast in aluminum using 3D-printed patterns, machined to final dimensions, and powder coated. [Mark] gives an excellent primer on creating patterns in CAD, including how to compensate for shrinkage and make allowance for draft. There are tons of tips to glean from these videos, and plenty of inspiration for anyone looking to achieve a professional fit and finish.
In the category of Best Appearing Spot Welder, we’ll give this one the nod. Runners-up from recent years include this plastic case model and this free-standing semi-lethal unit.
Continue reading “Not Just Your Average DIY Spot Welder”
Many years ago [ScorchWorks] built an electrical-discharge machining tool (EDM) and recently decided to write about it. And there’s a video embedded after the break.
The build is based on the designs described in the book “Build an EDM” by Robert Langolois. An EDM works by creating lots of little electrical discharges between an electrode in the desired shape and a material underneath a dielectric solvent bath. This dissolves the material exactly where the operator would like it dissolved. It is one of the most precise and gentle machining operations possible.
His EDM is built mostly out of found parts. The power supply is a microwave oven transformer rewired with 18 gauge wire to drop the voltage to sixty volts instead of the oven’s original boost to 1.5kV. The power resistor comes from a dryer element robbed from a unit sitting beside the road. The control board was etched using a hand traced schematic on the copper with a Sharpie.
The linear motion element are two square brass tubes, one sliding inside the other. A stepper motor slowly drives the electrode into the part. Coolant is pumped through the electrode which is held by a little 3D printed part.
The EDM works well, and he has a few example parts showing its ability to perform difficult cuts. Things such as a hole through a razor blade., a small hole through a very small piece of thick steel, and even a hole through a magnet.
Continue reading “Homemade EDM Can Cut Through Difficult Materials Like Magnets With Ease”
Welding is one of those things that takes minutes to learn and years to master. It requires coordination, strength, and a good pair of eyes. This vocational guidance video from the early 1940s touches on these points and more for those considering careers in welding. The narrator jumps right in, discussing welding types, equipment operation, and employment opportunities in both the welding field itself and other fields that use welding techniques.
Oxy-acetylene welding is one of the oldest methods of fusing metal. A flame fueled by a specific mixture of pure oxygen and acetylene gas heats the metal welding rod and the work piece to plasticity, which allows them to join together. An oxy-acetylene setup can also be used to cut metal, though a special cutting torch with a kind of oxygen turbo boost lever is required. The work piece is heated to red-hot at the point along the edge where the cut will start. The oxygen-rich flame will cut right through the piece.
Continue reading “Retrotechtacular: So You Want To Be A Weldor”
[Bob] was having trouble keeping up with his water troughs. He had to constantly check them to make sure they weren’t empty, and he always found that the water level was lower than he thought. He decided it was time to build his own solution to this problem. What he ended up with was a water level sensor made from PVC pipe and a few other components.
The physical assembly is pretty simple. The whole structure is made from 1/2″ PVC pipe and fittings and is broken into four nearly identical sensor modules. The sensors have an electrode on either side. The electrodes are made from PVC end caps, sanded down flat at the tip. A hole is then drilled through the cap to accommodate a small machine screw. The screw threads are coated in joint compound before the screw is driven into the hole, creating its own threads. These caps are placed onto small sections of PVC pipe, which in turn connect to a four-way PVC cross connector.
On the inside of the electrode cap, two washers are placed onto the screw. A stranded wire is placed between the washers and then clamped in place with a nut. All of the modules are connected together with a few inches of pipe. [Bob] measured this out so it would fit appropriately into his trough, but the measurements can easily be altered to fit just about any size container. The wires all route up through the pipe. The PVC pipe is cemented together to keep the water out. The joint compound prevents any leaks at the electrodes.
A piece of CAT 5 cable connects the electrodes to the electronics inside of the waterproof controller box. The electronics are simple. It’s just a simple piece of perfboard with an XBee and a few transistors. The XBee can detect the water level by testing for a closed circuit between the two electrodes of any sensor module. The water acts as a sort of switch that closes the circuit. When the water gets too low, the circuit opens and [Bob] knows that the water level has lowered. The XBee is connected to a directional 2.4GHz antenna to ensure the signal reaches the laptop several acres away. Continue reading “Wireless Water Level Sensor From PVC Pipe”