Supercon 2024 SAO Petal KiCad Redrawing Project

November 19, 2024 by Chris Lott 4 Comments

Last week I completed the SAO flower badge redrawing task, making a complete KiCad project. Most of the SAO petals are already released as KiCad projects, except for the Petal Matrix. The design features 56 LEDs arranged in eight spiral arms radiating from the center. What it does not feature are straight lines, right angles, nor parts placed on a regular grid.

Importing into KiCad

Circuit Notes for LEDs, Thanks to [spereinabox]

I followed the same procedures as the main flower badge with no major hiccups. This design didn’t have any released schematics, but backing out the circuits was straightforward. It also helped that user [sphereinabox] over on the Hackaday Discord server had rung out the LED matrix connections and gave me his notes.

Grep Those Positons

I first wanted to only read the data from the LEDs for analysis, and I didn’t need the full Kicad + Python scripting for that. Using grep on the PCB file, you get a text file that can be easily parsed to get the numbers. I confirmed that the LED placements were truly as irregular as they looked.

My biggest worry was how obtain and re-apply the positions and angles of the LEDs, given the irregular layout of the spiral arms. Just like the random angles of six SAO connector on the badge board, [Voja] doesn’t disappoint on this board, either. I fired up Python and used Matplotlib to get a visual perspective of the randomness of the placements, as one does. Due to the overall shape of the arms, there is a general trend to the numbers. But no obvious equation is discernable.

Continue reading “Supercon 2024 SAO Petal KiCad Redrawing Project” →

Supercon 2024 Flower SAO Badge Redrawing In KiCad

October 31, 2024 by Chris Lott 12 Comments

Out of curiosity, I redrew the Supercon Vectorscope badge schematics in KiCad last year. As you might suspect, going from PCB to schematic is opposite to the normal design flow of KiCad and most other PCB design tools. As a result, the schematics and PCB of the Vectorscope project were not really linked. I decided to try it again this year, but with the added goal of making a complete KiCad project. As usual, [Voja] provided a well drawn schematic diagram in PDF and CorelDRAW formats, and a PCB design using Altium’s Circuit Maker format (CSPcbDoc file). And for reference, this year I’m using KiCad v8 versus v7 last year.

Importing into KiCad

This went smoothly. KiCad imports Altium files, as I discovered last year. Converting the graphic lines to traces was easier than before, since the graphical lines are deleted in the conversion process. There was a file organizational quirk, however. I made a new, empty project and imported the Circuit Maker PCB file. It wasn’t obvious at first, but the importing action didn’t make use the new project I had just made. Instead, it created a completely new project in the directory holding the imported Circuit Maker file. This caused a lot of head scratching when I was editing the symbol and footprint library table files, and couldn’t figure out why my edits weren’t being seen by KiCad. I’m not sure what the logic of this is, was an easy fix once you know what’s going on. I simply copied everything from the imported project and pasted it in my new, empty project. Continue reading “Supercon 2024 Flower SAO Badge Redrawing In KiCad” →

Zero To Custom MacroPad In 37 Easy Steps

October 21, 2024 by Dave Rowntree 5 Comments

[Jeremy Weatherford] clearly has a knack for explaining projects well enough for easy reproduction but goes way further than most and has created a four-part YouTube series detailing every step from project inception to the final assembly, covering all aspects of 3D modelling and PCB design for a custom MacroPad design. Many tools are introduced along the way, all of which help reduce complexity and, by extension, the scope for errors. As every beginner hacker knows, early successes breed confidence and make for better and more ambitious projects.

Part 1 covers the project motivation and scope and introduces a keyboard layout editor tool. This tool allows one to take a layout idea and generate a JSON file, which is then used to drive keyboard tools. XYZ to produce a usable KiCAD project. The tool only generates a PCB project and an associated netlist file. No schematic is created; you don’t need one for a simple layout.

Part 2 is a walkthrough of the design process in KiCAD, culminating in ordering the PCB from JLCPCB and assembling the surface-mount parts. This particular design uses a controller based on the Sea-Picro RP2040 module, but there are many options if you have other preferences. [Jeremy] shows what’s possible with the selected suppliers, but you need not follow this step precisely if you have other ideas or want to use someone local.

Part 3 covers exporting the mechanical aspects of the PCB out of KiCAD and into a 3D CAD program, specifically OnShape. [Jeremy] covers some crucial details, such as how to read the mechanical drawing of the keys to work out where to place the top plate. It’s very easy to plough straight in at this stage and make a design which cannot be assembled! The plan is to use a simple laser-cut box with a bottom plate with mounting holes lining up with those on the PCB. A Top plate is created by taking the outline of the PCB and adding a little margin. An array of rectangular cutouts are designed for the keys to protrude, lining up perfectly with where the keys would be when mounted on the PCB below. The sides of the case are formed from laser-cut sections that lock into each other and the laser-cut base—using the laser joint feature-script addon tool from the OnShape community channel. A second feature script addon is used to auto-layout the laser-cut components onto a single sheet. A CAM application called Kiri Moto is used to export for laser cutting and is available on the OnShape store.

Continue reading “Zero To Custom MacroPad In 37 Easy Steps” →

Your Battery Holder Is Also Your Power Switch With ToggleSlot

October 15, 2024 by Dave Rowntree 23 Comments

We really like PCB-level hacks, especially ones that show ingenuity in solving a real problem while being super cheap to implement. Hackaday.IO user [Steph] wanted a cheap way to switch a wearable on and off without having to keep popping out the battery, so they came up with a tweaked battery footprint, which is also a simple slide switch.

Most people making badges and wearables will follow the same well-trodden path of just yanking out the cell or placing some cheap switch down and swallowing the additional cost. For [Steph], the solution was obvious. By taking a standard surface-mount CR2032 button cell holder footprint, extending its courtyard vertically, and moving the negative pad up a smidge, the battery can be simply slid up to engage the pad and slid down to disengage and shut off the juice. The spring section of the positive terminal keeps enough pressure on the battery to prevent it from sliding out, but if you are worried, you can always add a dummy pad at the bottom, as well as a little solder bump to add a bit more security.

Now, why didn’t we think of this before? The KiCad footprint file can be downloaded from the project GitHub page, imported into your project and used straight away.

Many of our gadgets are powered by CR2032 cells—so many so that eliminating the need for them leads to interesting projects, like this sweet USB-powered CR2032 eliminator. But how far can you push the humble cell? Well, we held a contest a few years ago to find out!

Illustrated Kristina with an IBM Model M keyboard floating between her hands.

Keebin’ With Kristina: The One With The KiCad Plugin

August 8, 2024 by Kristina Panos 2 Comments

Image by [fata1err0r81] via reddit

The most striking feature of the Tenshi keyboard has to be those dual track pads. But then you notice that [fata1err0r81] managed to sneak in two extra thumb keys on the left, and that those are tilted for comfort and ease of actuation.

The name Tenshi means ‘angel’ in Japanese, and creator [fata1err0r81] says that the track pads are the halos. Each one slides on a cool 3D-printed track that’s shaped like a half dovetail joint, which you can see it closer in this picture.

Tenshi uses a pair of RP2040 Zeros as controllers and runs QMK firmware. The track pads are 40 mm each and come from Cirque. While the Cirques have been integrated into QMK, the pull request for ZMK has yet to be merged in. And about those angled keys — [fata1err0r81] says they tried risers, but the tilting feels like less effort. Makes total sense to me, but then again I’m used to a whole keyboard full of tilted keys.

Continue reading “Keebin’ With Kristina: The One With The KiCad Plugin” →

Hacker Tactic: Single-PCB Panels

July 17, 2024 by Arya Voronova 35 Comments

Ordering a PCB? Two of them? Three? Five? For about eight years now, I’ve been regularly ordering large numbers of different PCBs, and, naturally, have developed a toolkit to make things smoother. One trick is PCB panelization, and you should really know about it.

You might’ve encountered PCB panels already. Perhaps, if you order PCBA at a fab, you will get your board returned in a whole new form-factor, with rails on the sides that you have to snap off before your PCB is usable. Those rails are used so that your PCBs are easier to handle during assembly, but that’s far from the only reason why you would make a panel.

If you need multiple pieces of a PCB, your fab may say that building 50 pcs is classified as “large batch” and that takes longer than 30 days, which delays your entire PCB order. I’ve been there, five years ago, running out of time right before Chinese New Year. The fix was simple – I made a 2×2 panel and ordered that in quantity of 10-15. Panelization might be a little more expensive, or maybe even cheaper, but, most importantly, it will be faster.

In a few hours’ time, I sat down, figured out that KiCad has built-in features for panelization, and ordered panels instead of separate PCBs. Thanks to that, I made the Chinese New Year deadline that year and could successfully restock my store, letting me earn a fair bit of money instead of keeping a popular product out-of-stock – ultimately, helping my family stay up on rent that month.

Panelization lets you hack around many PCB ordering and assembly limitations, and I’ve only gotten started – there’s way way more! For now, let’s sort out panelizing multiples of the same PCB. As long as your boards are using KiCad (or KiCad-converted from Eagle/EasyEDA/Altium/gerbers), there’s no better software than KiKit.

Continue reading “Hacker Tactic: Single-PCB Panels” →

An example of the case generated for a simple PCB, being shown in the OpenSCAD viewer

Turbocase Generates A PCB Shell For You

June 3, 2024 by Arya Voronova 23 Comments

Our PCBs greatly benefit from cases – what’s with all the pins that can be accidentally shorted, connectors that stick out of the outline, and cables pulling the board into different directions. Designing a case for your PCB might feel like a fair bit of effort – but it likely isn’t, thanks to projects like turbocase from [Martijn Braam].

This script generates simple and elegant OpenSCAD cases for your KiCad PCBs – you only need to draw a few extra lines in the PCB Editor, that’s it. It makes connector openings, too – add a “Height” property to your connector footprints to have them be handled automatically. Oh, and there’s a few quality-of-life features – if your project has mounting holes, the script will add threaded-insert-friendly standoffs to the case; yet another argument for adding mounting holes to your boards, in case you needed more.

Installing the script is a single line, running it is merely another, and that will cover an overwhelming majority of boards out there; the code is all open too, of course. Want some more customization? Here’s some general project enclosure tutorials for OpenSCAD, and a KiCad-friendly StepUp tutorial. Oh, and of course, there’s many more ways to enclose PCBs – our own [Bob Baddeley] has written a guide to project enclosures that you are bound to learn new things from.

We thank [adistuder] for sharing this with us!