Repairing A Component On A Flex Connector

It used to be you could crack open a TV or radio and really work on the components inside. The smallest thing in there was maybe a disc capacitor a little smaller than your pinky’s nail. Nowadays, consumer electronic boards are full of tiny SMD components. Luckily [StezStix Fix?] has a microscope and the other tools you need. Someone sent him an Amazon Echo Show with a bad touchscreen. Can it be fixed?

The video below shows that it can, but there’s a twist. The bad capacitor was mounted on one of those flexible PCB cables that are so hard to work with. It is hard enough not to damage these when you aren’t trying to remove and replace a component from the surface of the cable.

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Marimbatron: A Digital Marimba Prototyping Project

The Marimbatron is [Leo Kuipers] ‘s final project as part of the Fab Academy program supervised by [Prof. Neil Gershenfeld] of MIT’s Center for Bits and Atoms. The course aims to teach students how to leverage all the fab lab skills to create unique prototypes using the materials at hand.

The final polyurethane/PET/Flex PCB stack-up for the sensor pad

Fortunately, one of the main topics covered in the course is documentation, and [Leo] has provided ample material for review. The marimba consists of a horizontal series of wooden bars, each mounted over a metal resonator tube. It is played similarly to the xylophone, with a piano-type note arrangement, covering about five octaves but with a lower range than the xylophone. [Leo] converted this piano-type layout into a more logical grid arrangement. The individual pads are 3D printed in PETG and attached to a DIY piezoresistive pressure sensor made from a graphite-sprayed PET sheet laid upon a DIY flexible PCB. A central addressable LED was also included for indication purposes. The base layer is made of cast polyurethane, formed inside a 3D-printed rigid mould. This absorbs impact and prevents crosstalk to nearby sensors. The sensor PCB was initially prototyped by adhering a layer of copper tape to a layer of Kapton tape and cutting it out using a desktop vinyl cutter. While this method worked for the proof of concept, [Leo] ultimately outsourced the final version to a PCB manufacturer. The description of prototyping the sensor and dealing with over-moulding was particularly fascinating.

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Bespoke Implants Are Real—if You Put In The Time

A subset of hackers have RFID implants, but there is a limited catalog. When [Miana] looked for a device that would open a secure door at her work, she did not find the implant she needed, even though the lock was susceptible to cloned-chip attacks. Since no one made the implant, she set herself to the task. [Miana] is no stranger to implants, with 26 at the time of her talk at DEFCON31, including a couple of custom glowing ones, but this was her first venture into electronic implants. Or electronics at all. The full video after the break describes the important terms.

The PCB antenna in an RFID circuit must be accurately tuned, which is this project’s crux. Simulators exist to design and test virtual antennas, but they are priced for corporations, not individuals. Even with simulators, you have to know the specifics of your chip, and [Miana] could not buy the bare chips or find a datasheet. She bought a pack of iCLASS cards from the manufacturer and dissolved the PVC with acetone to measure the chip’s capacitance. Later, she found the datasheet and confirmed her readings. There are calculators in lieu of a simulator, so there was enough information to design a PCB and place an order.

The first batch of units can only trigger the base station from one position. To make the second version, [Miana] bought a Vector Network Analyzer to see which frequency the chip and antenna resonated. The solution to making adjustments after printing is to add a capacitor to the circuit, and its size will tune the system. The updated design works so a populated board is coated and implanted, and you can see an animated loop of [Miana] opening the lock with her bare hand.

Biohacking can be anything from improving how we read our heart rate to implanting a Raspberry Pi.

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Flexible Actuator Flaps For 100,000,000 Cycles Without Failure

Flexible PCBs are super-useful things, but they can have a limited fatigue life. [Carl Bugeja] has been using them to create flexible actuators, though, and he’s getting an amazing 100,000,000 cycles out of them after some rigorous development.

[Carl] explores all manner of optimizations to his flippy actuators in the video. He tried making them oscillate faster by putting a hole in the middle to reduce drag. Other tricks include getting the arm thickness just right, and experimenting with rigidity through adding or removing sections of soldermask.

Fundamentally, though, he learned the key to longevity laid in the copper traces on the flex PCBs themselves. After enough flexural cycles, the traces would fail, killing the actuator. He experimented with a variety of solutions, eventually devleoping a ruggedized two-arm version of his actuator. Twenty samples were put to the test, oscillating at 25 Hz for two weeks straight. All samples survived the test, in which they were put through around 107,820,000 cycles.

[Carl] has put in plenty of hard work on this project, and his actuators have come a long way since we saw them last. He hopes to use the better actuators to improve his FlexLED display. Video after the break.

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Supercon 2022: Samy Kamkar’s Glowing Breath

Sometimes the journey itself is the destination. This one started when [Samy] was 10 and his mom bought a computer. He logged on to IRC to talk with people about the X-Files and was WinNuked. Because of that experience, modulo a life of hacking and poking and playing, the talk ends with a wearable flex-PCB Tesla coil driving essentially a neon sign made from an ampule of [Samy]’s own breath around his neck. Got that? Buckle up, it’s a rollercoaster.

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Sticker Brings The Heat

[Carl] is always looking at making heater plates for PCB reflow and other applications. In his latest video, he shows how he is using thin flexible PCBs with adhesive backs as stickers that get hot. You can find gerber files and design files on GitHub.

You might think that this is a pretty simple thing to do with a flex PCB, but it turns out while the PCB might be flexible, the traces aren’t and so the typical long traces you see in a heater won’t allow the sticker to bend, which is a problem if you want to wrap it around, say, a coffee mug.

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Dreaming Of A Transparent (PCB) Christmas

[Carl] wanted to put his force sensors on a transparent PCB and had to ask his board vendor for a special sample. Flexible PCBs are available on transparent substrates made of PET, but they are not as common as polyimide boards. As [Carl] found out, these boards are a bit thicker, a bit less flexible, and don’t hold up to very high heat as well as the standard boards. Undeterred, he designed a 3D Christmas tree using the clear boards. The result that you can see in the video below looks pretty good and would have been hard to duplicate with conventional means.

When you build the board it is as a flat spiral, but lifting it in the center allows it to expand into a conical tree shape. The circuit itself is just an LED blinker, but the flexible board is the interesting part.

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