pcb

615 Articles

Integrated BMS Makes Battery Packs Easy

March 26, 2025 by 41 Comments

Lithium technology has ushered in a new era of batteries with exceptionally high energy density for a reasonably low cost. This has made a lot possible that would have been unheard of even 20 years ago such as electric cars, or laptops that can run all day on a single charge. But like anything there are tradeoffs to using these batteries. They are much more complex to use than something like a lead acid battery, generally requiring a battery management system (BMS) to keep the cells in tip-top shape. Generally these are standalone systems but [CallMeC] integrated this one into the buswork for a battery pack instead.

The BMS is generally intended to make sure that slight chemical imbalances in the battery cells don’t cause the pack to wear out prematurely. They do this by maintaining an electrical connection to each cell in the battery so they can charge them individually when needed, making sure that they are all balanced with each other. This BMS has all of these connections printed onto a PCB, but also included with the PCB is the high-power bus that would normally be taken care of by bus bar or nickel strips. This reduces the complexity of assembling the battery and ensures that any time it’s hooked up to a number of cells, the BMS is instantly ready to go.

Although this specific build is meant for fairly large lithium iron phosphate batteries, this type of design could go a long way towards making quick battery packs out of cells of any type of battery chemistry that typically need a BMS system, from larger 18650 packs or perhaps even larger cells like those out of a Nissan Leaf.

Supercon 2024: A New World Of Full-Color PCBs

March 26, 2025 by 12 Comments

Printed circuit boards were once so simple. One or two layers of copper etched on a rectangular fiberglass substrate, with a few holes drilled in key locations so components could be soldered into place. They were functional objects, nothing more—built only for the sake of the circuit itself.

Fast forward to today, and so much has changed. Boards sprout so many layers, often more than 10, and all kinds of fancy geometric features for purposes both practical and pretty. But what catches they eye more than that, other than rich, saturated color? [Joseph Long] came to the 2024 Hackaday Supercon to educate us on the new world of full color PCBs.

Continue reading “Supercon 2024: A New World Of Full-Color PCBs” →

Glow In The Dark PCBs Are Pretty Cool

March 24, 2025 by 11 Comments

What if circuit boards could glow in the dark? It’s a fun question, and one [Botmatrix] sought to answer when approached by manufacturer PCBWay to run a project together. It turns out that it’s quite possible to make glowing PCBs, with attractive results. (Video after the break.)

Specifically, PCBWay has developed a workable glow-in-the-dark silkscreen material that can be applied to printed circuit boards. As a commercial board house, PCBWay hasn’t rushed to explain how precisely they pulled off this feat, but we don’t imagine that it involved anything more than adding some glow-in-the-dark powder to their usual silkscreen ink, but we can only speculate.

On [Botmatrix]’s end, his video steps through some neat testing of the performance of the boards. They’re tested using sensors to determine how well they glow over time.

It might seem like a visual gimmick, and to an extent, it’s just a bit of fun. But still, [Botmatrix] notes that it could have some practical applications too. For example, glow-in-the-dark silkscreen could be used to highlight specific test points on a board or similar, which could be instantly revealed with the use of a UV flashlight. It’s an edge case, but a compelling one. It’s also likely to be very fun for creating visually reactive conference badges or in other applications where the PCB plays a major cosmetic role.

[Botmatrix] says these are potentially the first commercially-available glow-in-the-dark printed PCBs. We love glow in the dark stuff; we’ve even explored how to make your own glowing material before, too. .

Continue reading “Glow In The Dark PCBs Are Pretty Cool” →

Aluminum Business Cards Make Viable PCB Stencils

March 21, 2025 by 25 Comments

[Mikey Sklar] had a problem—namely, running low on the brass material typically used for making PCB stencils. Thankfully, a replacement material was not hard to find. It turns out you can use aluminum business card blanks to make viable PCB stencils.

Why business card blanks? They’re cheap, for a start—maybe 15 cents each in quantity. They’re also the right thickness, at just 0.8 mm 0.18 mm, and they’re flat, unlike rolled materials that can tend to flip up when you’re trying to spread paste. They’re only good for small PCBs, of course, but for many applications, they’ll do just fine.

To cut these, you’ll probably want a laser cutter. [Mikey] was duly equipped in that regard already, which helped. Using a 20 watt fiber laser at a power of 80%, he was able to get nice accurate cuts for the stencils. Thanks to the small size of the PCBs in question, the stencils for three PCBs could be crammed on to a single card.

If you’re not happy with your existing PCB stencil material, you might like to try these aluminium blanks on for size. We’ve covered other stenciling topics before, too.

Continue reading “Aluminum Business Cards Make Viable PCB Stencils” →

Soviet ZX Spectrum clone on a table

ZX Spectrum, Soviet Style: A 44-IC Clone You Can Build

March 10, 2025 by 12 Comments

If you’ve ever fancied building a ZX Spectrum clone without hunting down ancient ULAs or soldering your way through 60+ chips, [Alex J. Lowry] has just dropped an exciting build. He has recreated the Leningrad-1, a Soviet-built Spectrum clone from 1988, with a refreshingly low component count: 44 off-the-shelf ICs, as he wrote us. That’s less than many modern clones like the Superfo Harlequin, yet without resorting to programmable logic. All schematics, Gerbers, and KiCad files are open-source, listed at the bottom of [Alex]’ build log.

The original Leningrad-1 was designed by Sergey Zonov during the late Soviet era, when cloning Western tech was less about piracy and more about survival. Zonov’s design nailed a sweet spot between affordability and usability, with enough compatibility to run 90-95% of Spectrum software. [Alex]’ replica preserves that spirit, with a few 21st-century tweaks for builders: silkscreened component values, clever PCB stacking with nylon standoffs, and a DIY-friendly mechanical keyboard hack using transparent keycaps.

While Revision 0 still has some quirks – no SCART color output yet, occasional flickering borders with AY sound – [Alex] is planning for further improvements. Inspired to build your own? Read [Alex]’ full project log here.

Custom Touchpad PCBs Without The Pain

March 6, 2025 by 11 Comments

Many of us use touch pads daily on our laptops, but rarely do we give much thought about what they really do. In fact they are a PCB matrix of conductive pads, with a controller chip addressing it and sensing the area of contact. Such a complex and repetitive pattern can be annoying to create by hand in an EDA package, so [Timonsku] has written a script to take away the work.

It starts with an OpenSCAD script (originally written by Texas Instruments, and released as open source) that creates a diamond grid, which can be edited to the required dimensions and resolution. This is then exported as a DXF file, and the magic begins in a Python script. After adjustment of variables to suit, it finishes with an Eagle-compatible board file which should be importable into other EDA packages.

We’ve never made a touchpad ourselves, but having dome other such repetitive PCB tasks we feel the pain of anyone who has. Looking at this project we’re struck by the thought that its approach could be adapted for other uses, so it’s one to file away for later.

This isn’t the first home-made touchpad project we’ve brought you.

CNC Router And Fiber Laser Bring The Best Of Both Worlds To PCB Prototyping

March 4, 2025 by 22 Comments

Jack of all trades, master of none, as the saying goes, and that’s especially true for PCB prototyping tools. Sure, it’s possible to use a CNC router to mill out a PCB, and ditto for a fiber laser. But neither tool is perfect; the router creates a lot of dust and the fiberglass eats a lot of tools, while a laser is great for burning away copper but takes a long time to burn through all the substrate. So, why not put both tools to work?

Of course, this assumes you’re lucky enough to have both tools available, as [Mikey Sklar] does. He doesn’t call out which specific CNC router he has, but any desktop machine should probably do since all it’s doing is drilling any needed through-holes and hogging out the outline of the board, leaving bridges to keep the blanks connected, of course.

Once the milling operations are done, [Mikey] switches to his xTool F1 20W fiber laser. The blanks are placed on the laser’s bed, the CNC-drilled through holes are used as fiducials to align everything, and the laser gets busy. For the smallish boards [Mikey] used to demonstrate his method, it only took 90 seconds to cut the traces. He also used the laser to cut a solder paste stencil from thin brass shim stock in only a few minutes. The brief video below shows the whole process and the excellent results.

In a world where professionally made PCBs are just a few mouse clicks (and a week’s shipping) away, rolling your own boards seems to make little sense. But for the truly impatient, adding the machines to quickly and easily make your own PCBs just might be worth the cost. One thing’s for sure, though — the more we see what the current generation of desktop fiber lasers can accomplish, the more we feel like skipping a couple of mortgage payments to afford one.

Continue reading “CNC Router And Fiber Laser Bring The Best Of Both Worlds To PCB Prototyping” →