Three Ways To Etch Snazzy Brass Nameplates

January 25, 2018 by Dan Maloney 22 Comments

It’s the little touches that make a project, and a nice nameplate can really tie a retro build together. Such badges are easy enough to make with a CNC machine, but if you don’t have access to machine tools you can put chemistry to work for you with these acid-etched brass nameplates.

The etching method that [Switch and Lever] uses to get down to brass plaques will be intimately familiar to anyone who has etched a PCB before. Ferric chloride works as well on brass as it does on copper, and [Switch and Lever] does a good job explaining the chemistry of the etching process and offers some tips on making up etching solution from powdered ferric chloride. But the meat of the video below is the head-to-head test of three different masking methods.

The first method uses a laser printer and glossy paper ripped from a magazine to create a mask. The toner is transferred to the brass using an office laminator, and the paper removed with gentle rubbing before etching. For the other two candidates he uses a laser engraver to remove a mask of plain black spray paint in one case, or to convert special laser marking paint to a mask in the other.

We won’t spoil the surprise as to which gave the best results, but we think you’ll be pleased with how easy making classy nameplates can be. You can also use electrolytic methods for a deeper etch, but we think acid etching is a little more approachable for occasional use.

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Teardown: What’s Inside A Christmas Laser Projector?

January 22, 2018 by Tom Nardi 55 Comments

In the world of big-box retail, December 26th is a very special day. The Christmas music playing on the overhead speakers switches back to the family friendly Top 40, the store’s decorations get tossed in the compactor, and everything that’s even remotely related to the holiday is put on steep clearance. No more money to be made on the most commercialized of all holidays, so back to business as usual.

It’s in this narrow corridor of time, between the Great Holiday Unloading and the new spring products coming in, that you can find some fantastic deals on Christmas decorations. Not that long ago, this would hardly be exciting news for the readers of Hackaday. But Christmas lights and decorations have really started pushing the envelope in terms of technology: addressable RGB LED strands, Bluetooth controlled effects, and as of the last couple years, friggin’ lasers.

That’s right, you’ve seen them all over the neighborhood, probably took a few stray beams to the eye, you might even own your own. Laser projectors have been one of the most popular Christmas decorations for the last couple of years, and it’s not hard to see why. Just set the projector up in front of your house, and you’re done. No need to get on a ladder and string lights on the roof when you can just blast some directed energy up there instead.

Given how popular they are, I was surprised to see a lone Home Accents Holiday Multi-Color Light Projector on the clearance rack at Home Depot for around $14 a few days after Christmas. This was a 75% price reduction from normal MSRP, and right in that sweet impulse-buy price range. Let’s see what’s hiding inside!

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First Light: The Story Of The Laser

January 8, 2018 by Dan Maloney 36 Comments

Lasers are such a fundamental piece of technology today that we hardly notice them. So cheap that they can be given away as toys and so versatile that they make everything from DVD players to corneal surgery a reality, lasers are one of the building blocks of the modern world. Yet lasers were once the exclusive province of physicists, laboring over expansive and expensive experimental setups that seemed more the stuff of science fiction than workhouse tool of communications and so many other fields. The laser has been wildly successful, and the story of its development is an intriguing tale of observation, perseverance, and the importance of keeping good notes.

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Afroman Teaches Intro To Servos, Builds Laser Turret

January 7, 2018 by Kristina Panos 10 Comments

After a longish hiatus, we were pleased to see a new video from [Afroman], one of the most accessible and well-spoken teachers the internet has to offer. If you’re new to electronics, see the previous sentence and resolve to check out his excellent videos. The new one is all about servos, and it culminates in a simple build that provides a foundation for exploring robotics.

[Afroman] leaves no gear unturned in his tour de servo, which is embedded after the break. He explains the differences between open vs. closed loop motor systems, discusses the different sizes and types of servos available, and walks through the horns and pigtails of using them in projects. Finally, he puts this knowledge to use by building a laser turret based on a pan-tilt platform.

The Arduino-driven turret uses two micro servos controlled with pots to move by degrees in X/Y space. Interestingly, [Afroman] doesn’t program the board in the Arduino IDE using wiring. Instead, he uses an open-source microcontroller language/IDE called XOD that lets you code by building a smart sort of schematic from drag-and-drop components and logic nodes. Draw the connections, assign your I/O pin numbers, and XOD will compile the code and upload it directly to the board.

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Monoprice Mini Laser Engraver Hack

December 26, 2017 by Al Williams 12 Comments

There’s an old saying, that in theory there’s no difference between theory and practice, but in practice there is. That sentiment could easily be applied to refitting a 3D printer to hold a laser. There shouldn’t be much to it, rig up a laser module to turn on under computer control, mount it to your hot end carriage and off you go. In practice, though there are other considerations to account for. If you have a Monoprice Mini Select, you can start with instructions from [drodrii] for adding a laser to your printer.

Although [drodrii] mentions that you need a second 3D printer to make a bracket for the laser, we think you should be able to print it on the Mini as long as you do it before the first step of removing the hot end. However, since your laser module might not exactly match the one used in this project, you’d have to get it right the first time if you don’t have another 3D printer. Of course, you could remove the laser gear, remount the hot end, print a new bracket and start over, but that’d be a drag.

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Improving Cheap Laser Engravers For PCB Fabrication

December 22, 2017 by Brian Benchoff 24 Comments

A few months ago, [Marco] picked up a cheap, cheap, cheap laser engraver from one of the familiar Chinese resellers. It’s a simple affair with aluminum extrusions, a diode laser, and a control board that seems like it was taken from a 3D printer controller designed five years ago. Now, [Marko] is building some upgrades for this engraver and his PCB production skills have gone through the roof.

The laser engraver [Marko] picked up is called the EleksMaker, and lucky for him there are quite a few upgrades available on Thingiverse. He found two 3D printable parts, one that keeps the belt parallel to the aluminum extrusion, and another that provides adjustable x-axis tightness on the belt. With these two mods combined, [Marko] actually has a nice, smooth motion platform that’s more precise and makes better engravings.

These upgrades weren’t all 3D-printable; [Marko] also got his hands on a few Trinamic TMC2130 stepper motor drivers. These stepper drivers are the new hotness in 3D printing and other desktop CNC machines, and looking at the waveform in an oscilloscope, it’s easy to see why. These drivers produce a perfectly smooth waveform via interpreted microstepping, and they’re almost silent in operation. That’s terrible if you want to build a CNC chiptune player, but great if you want smooth engraving on a piece of copper clad board.

This project has come a long way since the last time we took a look at it a few months ago, and the results just keep getting better. [Marko] is making real PCBs with a laser engraver that cost less than $200, and the upgrades he’s already put into it don’t add up to much, either. You can take a look at [Marko]’s progress in the video below.

Thanks [dechemist] for the tip.

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Home-Brew Ruby Laser Packs A Wallop

December 19, 2017 by Dan Maloney 31 Comments

In the past half-century, lasers have gone from expensive physics experiments using rods of ruby to cheap cutting or engraving tools, and toys used to tease cats. Advances in physics made it all possible, but it turns out that ruby lasers are still a lot of fun to play with, if you can do it without killing yourself.

With a setup that looks like something from a mad scientist movie set, [styropyro]’s high-powered laser is a lot closer to the ray gun of science fiction than the usual lasers we see, though hardly portable. The business end of the rig is a large ruby rod nestled inside a coiled xenon flash lamp, which in turn is contained within a polished reflector. The power supply for the lamp is massive — microwave oven transformers, a huge voltage multiplier, and a bank of capacitors that he says can store 20 kilojoules. When triggered by a high-voltage pulse from a 555 oscillator and an old car ignition coil, the laser outputs a powerful pulse of light, which [styropyro] uses to dramatic effect, including destroying his own optics. We’d love to hear more about the power supply design; that Cockcroft-Walton multiplier made from PVC tubes bears some exploration.

Whatever the details, the build is pretty impressive, but we do urge a few simple safety precautions. Perhaps a look at [Ben Krasnow]’s 8-kJ ruby laser would help.

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