Hacking Printed Circuit Board To Create Casing And Instrument Panels

August 9, 2025 by John Elliot V 11 Comments

Over on Hackaday.io our hackers [Angelo] and [Oscarv] are making a replica of the PDP-1. That is interesting in and of itself but the particularly remarkable feature of this project is its novel use of printed circuit boards for casing and instrument panels.

What does that mean in practice? It means creating a KiCad file with a PCB for each side of the case/panel. These pieces can then be ordered from a board house and assembled. In the video below the break you will see an example of putting such a case together. They use sticky tape for scaffolding and then finish things off by soldering the solder joints on each edge together.

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Open-Source, Flexible E-Reader

August 3, 2025 by Bryan Cockfield 30 Comments

Although the most popular e-reader by far is the Kindle, some argue that its primary use isn’t even as an e-reader at all but rather as a storefront for one of the world’s richest companies. For those who want user-focused consumer electronics instead, we’ll often reach for something more untethered, like an off-brand ebook that’s nothing more than an Android tablet with an e-paper display or even a jailbroken Kindle freed from the chains of Amazon. But as our 555 enthusiast community continually points out, even these are overkill for reading books. Enter the ZEReader.

The ZEReader started out as a bachelor’s engineering thesis project by [Anna-Lena Marx], whose goal was an open-source, microcontroller-based e-reader instead of the Linux or Android ones most commonly available. She’s based the firmware around the Zephyr Real-Time Operating System, which is an RTOS geared towards embedded devices. With this as a backbone, it’s trivially easy to implement the e-reader on different microcontrollers as well as use a wide variety of screens. Although the firmware is a work-in-progress, it’s already mature enough to support all of the basics of an e-reader, such as reading .epub files, navigating through the book, and saving progress. It even includes basic HTML parsing.

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Transparent PCBs Trigger 90s Nostalgia

July 25, 2025 by Lewin Day 42 Comments

What color do you like your microcontroller boards? Blue? Red? Maybe white or black? Sadly, all of those are about to look old hat. Why? Well, as shared by [JLCPCB], this transparent Arduino looks amazing.

The board house produced this marvel using its transparent flexible printed circuit (FPC) material. Basically, the stuff they use for ribbon cables and flex PCBs, just made slightly differently to be see-through instead of vaguely brown.

The circuit in question is a Flexduino, an Arduino clone specifically designed to work on flexible substrates. It looks particularly good on this transparent material, with the LEDs glowing and the white silkscreen for contrast. If you like what you see, you can order your own circuits using this material directly from JLCPCB’s regular old order form.

Most of all, this project reminds us of the 1990s. Back then, you could get all kinds of games consoles and other electronics with transparent housings. There was the beloved PlayStation Crystal, while Nintendo did something similar with the N64 while adding a whole line of tinted color and charcoal versions too. Somehow seeing a bit of the inside of things is just cool. Even if, in some cases, it’s just to avoid smuggling in prisons.

It took decades before you could get custom PCBs quickly and easily. Now, board houses are competing for the enthusiast (consumer?) market, and competition is spurring development of crazy stuff like transparent and even glow in the dark PCBs. What next? We’re thinking edible, ROHS and WEEE be damned. Drop your thoughts in the comments.

Thanks to [George Graves] for the tip!

Hackaday Links: July 13, 2025

July 13, 2025 by Dan Maloney 8 Comments

There’s interesting news out of Wyoming, where a coal mine was opened this week. But the fact that it’s the first new coal mine in 50 years isn’t the big news — it’s the mine’s abundance of rare earth elements that’s grabbing the headlines. As we’ve pointed out before, rare earth elements aren’t actually all that rare, they’re just widely distributed through the Earth’s crust, making them difficult to recover. But there are places where the concentration of rare earth metals like neodymium, dysprosium, scandium, and terbium is slightly higher than normal, making recovery a little less of a challenge. The Brook Mine outside of Sheridan, Wyoming is one such place, at least according to a Preliminary Economic Assessment performed by Ramaco Resources, the mining company that’s developing the deposit.

The PEA states that up to 1,200 tons of rare earth oxides will be produced a year, mainly from the “carbonaceous claystones and shales located above and below the coal seams.” That sounds like good news to us for a couple of reasons. First, clays and shales are relatively soft rocks, making it less energy- and time-intensive to recover massive amounts of raw material than it would be for harder rock types. But the fact that the rare earth elements aren’t locked inside the coal is what’s really exciting. If the REEs were in the coal itself, that would present something similar to the “gasoline problem” we’ve discussed before. Crude oil is a mixture of different hydrocarbons, so if you need one fraction, like diesel, but not another, like gasoline, perhaps because you’ve switched to electric vehicles, tough luck — the refining process still produces as much gasoline as the crude contains. In this case, it seems like the coal trapped between the REE-bearing layers is the primary economic driver for the mine, but if in the future the coal isn’t needed, the REEs could perhaps be harvested and the coal simply left behind to be buried in the ground whence it came.

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Does Made-in-America Make Sense For PCB Prototyping?

July 6, 2025 by Tyler August 96 Comments

These are tough times for American hackers, and rife with uncertainty. Trade wars are on, off, on again– who can keep track? If you’re used to getting everything from China, that can really cramp your style. [Jeremy Cook] took the time to write up his experience prototyping with American-made PCBs, just in time for us to totally miss Independence Day.

The project was a simple nightlight, using a single LED, a photoresistor, a transistor, and a CR2032 battery. The CR2032 battery does complicate things, though: [Jeremy] figured out a neat way to hold the battery using a PCB cutout, but it needs to be a 0.8 mm board. (That’s going to matter in a moment.) He’s put that PCB on GitHub if you’re interested.

To start off, JLBPCB is the Chinese clearing house of choice for [Jeremy], and they quoted a very cheap $7.10 for 20 boards. The problem was that shipping across the Pacific Ocean, plus the ever-wavering tariff charge, brought the price to $48.08. About five dollars of which was from tariffs; the rest you can put down to the cost of jet fuel and the size of the Pacific Ocean.

On the other hand, OSH Park, was able to get [Jeremy] three of their pretty purple PCBs for $7.75 all-inclusive. Overall, since he’s prototyping and does not want 20 boards this revision, [Jeremy] saves quite a lot by staying local– including the environmental impact of shipping and laxer regulations in China, if that sort of thing matters to you.

The suprizing thing is the turnaround time: [Jeremy] got his pretty purple PCBs from OSH Park a full twenty days after ordering. Similar orders from China take only a week, which is just mind-blowing when you stop and think about the great honking ocean in the way. We could perhaps cut OSH Park some slack in that 0.8 mm boards are not the most common, but their quoted turnaround time for two-layer prototypes is minimum 12 days.

They do offer a “super-swift” option for two-layer boards, but then they lose on price. As [Jeremy] points out, there are always tradeoffs. If you’re really in a hurry, nothing’s faster than milling the boards yourself. Or you could go the old-school toner-transfer etching route.

Our thanks to [Jeremy] for the tip. If you’ve got a better way to prototype, do send us a tip about it. Also, please us know in the comments if you’ve tried an in-country PCB fabricator, and how it compared to the usual offerings from the PRC.

Using an SMD capacitor as a clip for flash media on a circuit board.

SMD Capacitor Doubles As Cheap SD Card Latch

July 4, 2025 by John Elliot V 41 Comments

Here’s a clever hack. Simple, elegant, and eminently cost-effective: using an SMD capacitor to hold your flash media in place!

This is a hack that can pretty much be summed up with just the image at the top of the page — a carefully placed SMD capacitor soldered to a routed tab makes for an extremely cost effective locking mechanism for the nearby SD card slot. There’s just enough flexibility to easily move the capacitor when its time to insert or eject your media.

It’s worth noting that the capacitor in this example doesn’t even appear to be electrically connected to anything. But there’s also no reason you couldn’t position one of the capacitors in your existing bill of materials (BOM). This form of mechanical support will be much cheaper than special purpose clips or mounts. Not a big deal for low-volume projects, but if you’re going high-volume this is definitely something to keep in mind.

If you’re just getting started with SMD capacitors then one of the first things to learn is how to solder them. Also, if you’re hoping to salvage them then try to look for newer equipment which is more likely to have SMD components than through-hole. If you’re planning to use your capacitors for… “capacitance” (how quaint), you can start by learning the basics. And if you want to know everything you can learn about the history of capacitors, too.

Thanks to [JohnU] for writing in to let us know about this one. Have your own natty hacks? Let us know on the tipsline!

The Keyboard Sinclair Never Made

June 2, 2025 by Heidi Ulrich 21 Comments

For those of us who’ve spent far too long hammering rubber keys into submission, a glorious solution has arrived. [Lee Smith] designed the ZX Mechtrum Deluxe, the ultimate keyboard upgrade for your beloved ZX Spectrum 48k. Thanks to [morefunmakingit], you can see this build-it-yourself mechanical mod below. It finally brings a proper spacebar and Spectrum-themed Wraith keycaps into your retro life.

The Metrum Deluxe is a full PCB redesign: no reused matrices or clunky membrane adapters here. [Lee Smith] got fed up with people (read: the community, plus one very persistent YouTuber) asking for a better typing experience, so he delivered. Wraith keycaps from AliExpress echo the original token commands and BASIC vibe, without going full collector-crazy. Best of all: the files are open. You can download the case on Printables and order the PCB through JLCPCB. Cherry on top (pun intended): you’ll finally have a spacebar your thumbs can be proud of.

So whether you’re into Frankenstein rigs or just want your Spectrum to stop feeling like an air mattress, check this video out. Build files and link to the keycaps can be found on Youtube, below the video.

Tip: if you foster a secret love for keyboards, don’t miss the Keebin’ with Kristina’s series on all sorts of keyboards.

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