A Compact SMD Reflow Hotplate Powered By USB-PD

January 9, 2024 by Dan Maloney 10 Comments

When it comes to home-lab reflow work, there are a lot of ways to get the job done. The easiest thing to do perhaps is to slap a PID controller on an old toaster oven and call it a day. But if your bench space is limited, you might want to put this compact reflow hotplate to work for you.

There are a lot of nice features in [Toby Chui]’s build, not least of which is the heating element. Many DIY reflow hotplates use a PCB heater, where long, thin traces in the board are used as resistive heating elements. This seems like a great idea, but as [Toby] explains in the project video below, even high-temperature FR4 substrate isn’t rated for the kinds of temperatures needed for some reflow profiles. His search for alternatives led him to metal ceramic heaters (MCH), which are commonly found in medical and laboratory applications. The MCH he chose was rated for 20 VDC at 50 watts — perfect for powering with USB-PD.

The heater sits above the main PCB on a Kapton-wrapped MDF frame with a thermistor to close the loop. While it’s not the biggest work surface we’ve seen, it’s a good size for small projects. The microcontroller is a CH552, which we’ve talked about before; aside from that and the IP2721 PD trigger chip needed to get the full 60 watts out of the USB-PD supply, there’s not much else on the main board.

This looks like a nice design, and [Toby] has made all the design files available if you’d like to give it a crack. Of course, you might want to freshen up on USB-PD before diving in, in which case we recommend [Arya]’s USB-PD primer.

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Throwback: USB Hotplate Used 30 Whole Ports

December 1, 2022 by Lewin Day 22 Comments

Once upon a time, USB was still hip, cool, and easy to understand. You could get up to 500 mA out of a port, which wasn’t much, but some companies produced USB cup warmers anyway which were a bit of a joke. However, one enterprising hacker took things further back in 2004, whipping up a potent USB hot plate powered by a cavalcade of ports.

The project was spawned after a USB cup warmer sadly failed to cook a decent fried egg. To rectify this, a souped-up version was built. The cup warmer was stripped of its original hardware, and fitted with six 2-ohm resistors instead. At 5 volts, each would draw 2.5 amps and the total power draw would be on the order of 75 watts. Each resistor would thus need five USB ports to power it to stay under the 500 mA limit, for a total of 30 USB ports in total. Six PCI-to-USB cards were installed in a motherboard for this purpose, providing the requisite ports. A 500 watt power supply meant the computer had plenty of juice to run the hot plate.

Cooking proved successful, generating a decent amount of heat to brown up some beef. Served with some white rice, it proved an adequate meal, though apparently with a noted taste of electronic components.

This wouldn’t be such a challenge today. USB-C is capable of delivering 100 watts through a single port at 20 volts and 5 amps. However, there’s something joyous and charming about cooking on a ridiculous hotplate running off 30 USB 1.1 ports. The ingenuity is to be applauded, and it is truly a project of its time.

PCB Hotplate Has Integrated Heating Element Traces

November 16, 2022 by Lewin Day 13 Comments

Normally when we talk about PCBs and hotplates, we’re talking about reflowing solder. In this build from [Arnov Sharma], though, the PCB itself is the hotplate!

The idea was to create a compact hotplate for easily reflowing small PCBs. To achieve that, [Arnov] designed a board with a thick coil trace that acts as a heating element. The full coil trace has a resistance of 1.9 ohms, and passing electricity through it generates plenty of heat. Running off a 12 volt supply, the mini hotplate is capable of reaching a maximum temperature of 214°C. Higher voltages can push that figure higher.

The board is intended to self-regulate, with an ATtiny13 onboard and a thermistor to measure temperature. However, in the initial design, this feature didn’t quite work properly. Version 2 is intended to include a better temperature sensor and a OLED screen for displaying the current temperature to the user.

We’ve seen other tiny hotplate builds before, too. They’re great for smaller projects and for hacking on the go! Video after the break.

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New controller PCB shown below the original one. The new PCB has an ESP module with an antenna, a lot of support circuitry, and all the same connectors that the original board does.

Controller For 946C Hotplate Adds Reflow Profile Upload Over BLE

September 30, 2022 by Arya Voronova 7 Comments

Reflow hotplates are a wonderful tool for PCB assembly if you can keep your designs single-sided. The 946C hotplate in particular has been on hackers’ radar for a while – a 200x200mm working surface hotplate available for under $100 is a decent investment. As with other reflow tools, it was a matter of time until someone made a replacement controller for it. This one, you’ll want to keep in mind – it’s a replacement controller project by [Arnaud Durand] and [Elias Rodriguez Martin], called Reflow946.

Keeping to best practices, the board is a drop-in replacement for the stock controller – swap cables over and go. The host processor is an ESP32, and it lets you can program reflow profiles in using BLE, with a Python application to help. The whole design is open-source and on GitHub, of course – keeping with best 3D printing traditions, you can already order the parts and PCBs, and then assemble them using the hotplate you’re about to upgrade. As far as aftermarket controllers go, here’s no doubt this board gives you way more control in reflow and lets you compensate for any possible subpar calibration while at it. Continue reading “Controller For 946C Hotplate Adds Reflow Profile Upload Over BLE” →

Reflow Hotplate Teardown Uncovers The Bare Minimum

March 10, 2022 by Al Williams 13 Comments

[EEforEveryone] is trying to find a good hot plate for reflow soldering. After trying one cheap unit, he got another one. He was a bit underwhelmed. The grounding was suspect and the bed wasn’t totally flat. He tore it apart and was surprised that there was very little inside. While the construction wasn’t perfect, it was better than the previous unit. You can see a video of the teardown and review below.

Before powering it up, the first order of business was to rewire the ground system. After that, it was time to try it. However, by confusing Fahrenheit and Centigrade, he set the temperature much higher than necessary which creating a little smoke. Fixing the temperature helped, but there was still a bit of a smoky smell that eventually subsided.

The verdict? The hot plate worked well enough, but you probably do want to check the ground wiring before using it. That’s often a good idea where cheap equipment is concerned, anyway. But the real takeaway is that it looks like you could homebrew something equivalent without much trouble. The controller is an off-the-shelf module. A switch and a plug aren’t hard to figure out. The heating element could be a silicone heater or PCB heater meant for a 3D printer.

Of course, there are other options. You could use a wok. Or why not a waffle iron? You can also make a custom PCB.

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Iron Becomes SMD Hot Plate

July 4, 2021 by Al Williams 20 Comments

Few things have changed our workshops more than surface mount components. In 1980 it would have been strange to see a hobby bench with a microscope, hot air equipment, tweezers, and all the other accouterments that are a necessity today. [Electronoobs] wanted a reflow hot plate and decided that he could repurpose a consumer laundry iron for the job. You can see the results in the video below.

Opening the iron revealed surprisingly simple circuitry, so the build has some additional parts along with a controller and an LCD, of course. The power requirement for the heating element is significant — 13 amps — so the plate uses a solid state relay to turn things on and off.

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Ask Hackaday: How Do You Make A Hotplate?

September 28, 2016 by Brian Benchoff 119 Comments

Greetings fellow nerds. The Internet’s favorite artificial baritone chemist has a problem. His hotplates burn up too fast. He needs your help to fix this problem.

[NurdRage] is famous around these parts for his very in-depth explorations of chemistry including the best ways to etch a PCB, building a thermometer probe with no instructions, and chemical synthesis that shouldn’t be performed by anyone without years of experience in a lab. Over the past few years, he’s had a problem: hotplates suck. The heating element is usually poorly constructed, and right now he has two broken hotplates on his bench. These things aren’t cheap, either: a bare-bones hotplate with a magnetic stirrer runs about $600.

Now, [NurdRage] is asking for help. He’s contacted a few manufacturers in China to get a hundred or so of these hotplate heating elements made. Right now, the cost for a mica and metal foil hotplate is about $30 / piece, with a minimum order quantity of 100. That’s $3,000 that could be better spent on something a bit more interesting than a heating element, and this is where you come in: how do you build the heating element for a hotplate, and do it cheaply?

If you buy a hotplate from the usual lab equipment supplier, you’ll get a few pieces of mica and a thin trace of metal foil. Eventually, the metal foil will oxidize, and the entire hotplate will stop working. Repairs can be done with copper tape, but by the time that repair is needed, the heating element is already on its way out.

The requirements for this heating element include a maximum temperature of around 350 ºC. That’s a fair bit hotter than any PCB-based heat bed from a 3D printer gets, so consider that line of reasoning a dead end. This temperature is also above what most resins, thermoplastics, and composites can handle, which is why these hotplates use mica as an insulator.

Right now, [NurdRage] will probably end up spending $3,000 for a group buy of these heating elements. That’s really not that bad – for the price of five hotplates, he’ll have enough heating elements to last through the rest of his YouTube career. There must be a better way, though, so if you have an idea of how to make a high-temperature heating element the DIY way, leave a note in the comments.