pcb

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CNC Your Own PCB With This Tutorial

March 3, 2019 by 26 Comments

It is getting so easy to order a finished printed circuit board that it is tough to justify building your own. But sometimes you really need a board right now. Or maybe you need a lot of fast iterations so you can’t wait for the postal service. [Thomas Sanladerer] shows how he makes PCBs with a CNC machine and has a lot of good advice in the video below.

He starts with Eagle, although, you could use any creation package. He shows what parameters he changes to make sure the traces don’t get eaten away and how to do the CAM job to get the files required to make the boards. If you don’t use Eagle, you’ll need to infer how to do similar changes and get the same kind of output.

We’ve only heard a few people pronounce Gerber (as in Gerber file) with a soft G sound, but we still knew what he meant. We have the same problem with GIF files. However, once you have Gebers, you can join the video’s workflow about 5 minutes in.

At that point, he uses FlatCAM to convert the Gerbers to a single G-code file that integrates the paths and drill files. There were a few tricks he used to make sure all the tracks are picked up. Other tricks include leveling a spoil board by just milling it down and mounting different size bits. He also has ideas on aligning the Z axis.

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Reverse Engineering Keeps Keck Telescopes On Track

February 26, 2019 by 13 Comments

Perched atop a dormant volcano far above the roiling tropical air of the Big Island of Hawai’i sit two of the largest optical telescopes in the world. Each 10-meter main mirror is but a single part of a magnificent machine weighing in at some 400 tons that needs to be positioned with incredible precision. Keeping Keck 1 and Keck 2 in peak operating condition is the job of a team of engineers and scientists, so when the servo amplifiers running the twelve motors that move each scope started to show their age, [Andrew] bit the bullet and rebuilt the obsolete boards from scratch.

The Keck telescopes were built over three decades ago, and many of the parts, including the problematic servo amps, are no longer made. Accumulated wear and tear from constant use and repeated repairs had taken their toll on the boards, from overheated components to lifted solder pads. With only some barely legible schematics of the original amplifiers to go by, [Andrew] reverse engineered new amps. Some substitutions for obsolete components were needed, the PCB design was updated to support SMD parts, and higher-quality components were specified, but the end result is essentially new amplifiers that are plug-in replacements for the original units. This should keep the telescopes on track for decades to come.

Not to sound jealous, but it seems like [Andrew] has a great gig. He’s shared a couple of his Keck adventures before, like the time a failed LED blinded the telescope. He’s also had a few more down-to-earth hacks, like fixing a dodgy LCD monitor and making spooky blinkeneyes for Halloween.

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Hackaday Links: February 24, 2019

February 24, 2019 by 20 Comments

Back To The Future Part II, released in 1989, told us the far-off future of 2015 would have flying cars, drones working for national newspapers, and self-lacing sneakers. Our best hope for flying cars is Uber, and that’s going to be hilarious when it fails. (Note to Uber: buy KSMO, Santa Monica airport, as an air taxi hub because that’s the most hilarious of all possible realities.) National newspapers — heck, even newspapers — don’t exist anymore. Self-lacing sneakers? Nike’s self-lacing sneakers brick themselves with a firmware update. Don’t worry, it’s only the left shoe.

HackSpace magazine Vol. 16 is out, and there’s a few pages dedicated to Tindie from the person who runs it, our fabulous [Jasmine]. There’s some good tips in here for Tindie sellers — especially shipping — and a good introduction to what Tindie actually is. The three-second elevator pitch of, ‘Etsy but for DIY electronics’ is not in the feature, though.

Is it duct tape or duck tape? That’s a silly question, because it’s ‘duck’ tape, but that’s not important. Gaffer tape is superior. [Ross Lowell], the inventor of gaffer tape, passed away last week at the age of 92.

[Peter Stripol] has a hobby of building ultralights in his basement. Actually, he has a hangar now, so everything’s good. His first two planes flew as Part 103 ultralights, however, there were design problems. [Peter] is using an electric powerplant, with motors and batteries, which is much lighter than a gas-chugging Rotax. However, he was still basing his designs on traditional ultralights. His now third build will be slightly more trimmed down, probably a little bit faster, and might just use 3D-printed control surfaces. Check out the intro to the mk3 airplane here.

[Matthias Wandel], the woodworking Canadian famous for designing the pantorouter, just built a three-legged stool. Sure, that doesn’t sound impressive, but check this out. All the weird mortises were done on the pantorouter, and there are some weird mortises here.

You’re only cool if you got chainz, so here’s some PCB chainz. This was done by [@jeffwurz] with OSHPark PCBs. The design, from as far as we can tell, is simple. It’s just a PCB without a soldermask, and a small cutout in one of the links. Assemble it into a chain, and if you’re clever, solder some resistor leads across the gap to make it a bit more solid.

ASMR, or officially, ‘autonomous sensory meridian response’, is the tingling sensation moving down your back induced by specific auditory (or visual) stimuli. That’s the scientific definition. On the Internet, it’s people breathing into microphones and smacking their lips. Yes, there are videos of this. Thousands of them. There are 11-year-old girls raking in the YouTube money posting ASMR videos. It’s weird and gross, and don’t get me started on slime videos. You’ve also got unboxing videos. The Raspberry Pi foundation found a way to combine ASMR with unboxing videos. I gotta respect the hustle here; ASMR and unboxing videos are some of the most popular content available, and the Pi foundation is not only combining the two, but doing so ironically. It’s exactly the content everyone wants to see, and it’ll bring in people who hate ASMR and unboxing videos. Someone over at the Pi foundation really knows what they’re doing here.

DIY Vacuum Table Enhances PCB Milling

January 28, 2019 by 18 Comments

CNC milling a copper-clad board is an effective way to create a PCB by cutting away copper to form traces instead of etching it away chemically, and [loska] has improved that process further with his DIY PCB vacuum table. The small unit will accommodate a 100 x 80 mm board size, which was not chosen by accident. That’s the maximum board size that the free version of Eagle CAD will process.

When it comes to milling PCBs, double-sided tape or toe clamps are easy solutions to holding down a board, but [loska]’s unit has purpose behind its added features. The rigid aluminum base and vacuum help ensure the board is pulled completely flat and held secure without any need for external fasteners or adhesives. It’s even liquid-proof, should cutting fluid be used during the process. Also, the four raised pegs provide a way to reliably make double-sided PCBs. By using a blank with holes to match the pegs, the board’s position can be precisely controlled, ensuring that the back side of the board is cut to match the front. Holes if required are drilled in a separate process by using a thin wasteboard.

Milling copper-clad boards is becoming more accessible every year; if you’re intrigued by the idea our own [Adil Malik] provided an excellent walkthrough of the workflow and requirements for milling instead of etching.

Video: Putting High Speed PCB Design To The Test

January 24, 2019 by 48 Comments

Designing circuit boards for high speed applications requires special considerations. This you already know, but what exactly do you need to do differently from common board layout? Building on where I left off discussing impedance in 2 layer Printed Circuit Board (PCB) designs, I wanted to start talking about high speed design techniques as they relate to PCBs.  This is the world of multi-layer PCBs and where the impedance of both the Power Delivery Network (PDN) and the integrity of the signals themselves (Signal Integrity or SI) become very important factors.

I put together a few board designs to test out different situations that affect high speed signals. You’ve likely heard of vias and traces laid out at right angles having an impact. But have you considered how the glass fabric weave in the board itself impacts a design? In this video I grabbed some of my fanciest test equipment and put these design assumptions to the test. Have a look and then join me after the break for more details on what went into this!

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A Drum Set In Your Pocket

January 22, 2019 by 3 Comments

Cargo pants can fit drumsticks in the pockets if you don’t mind them sticking out. They can also hold this drum set and still have enough room for a pair of headphones, some pens, and a small notebook. At least, guy’s cargo pants can fit all that. Now your pocket is decked out with enough music gear to compose and drum few drum loops and even scribble some notes. We can’t speak for [Tomash Ghz] carrying a notebook, but he wanted a drum set in his pocket badly enough to make a custom circuit board to bring to the 2017 Fasma Festival in Athens. He wrote code for a Teensy 3.2 which fits on the back of his PCB next to a 9V battery. Don’t be afraid, the smallest components are 0805 so even clumsy fingers will be able to build their own. The Gerber files and BOM are all available, so nothing is stopping you.

On the board, we find an array of op-amps to support headphone and line-level outputs, four big ole’ buttons to activate each type of drum: kick, tom, snare, and hat. Then we have four potentiometers to change the sound of each like pitch, decay/length, modulation, and distortion. Once the perfect pattern is recorded, it can be saved in non-volatile memory in case you run out of juice although it can run up to seven-and-a-half hours on one battery. If you find yourself invested in the hardware, there is also a video walk-through about using the drum machine so grab your notebook and beat it.

We have seen simpler drums in simpler chips, and even drums on an entirely different type of chip.

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The Embroidered Computer

January 16, 2019 by 5 Comments

By now we’ve all seen ways to manufacture your own PCBs. There are board shops who will do small orders for one-off projects, or you can try something like the toner transfer method if you want to get really adventurous. One thing we haven’t seen is a circuit board that’s stitched together, but that’s exactly what a group of people at a Vienna arts exhibition have done.

The circuit is stitched together on a sheet of fabric using traditional gold embroidery methods for the threads, which function as the circuit’s wires. The relays are made out of magnetic beads, and the entire circuit functions as a fully programmable, although relatively rudimentary, computer. Logic operations are possible, and a functional schematic of the circuit is also provided. Visitors to the expo can program the circuit and see it in operation in real-time.

While this circuit gives new meaning to the term “wearables”, it wasn’t intended to be worn although we can’t see why something like this couldn’t be made into a functional piece of clothing. The main goal was to explore some historic techniques of this type of embroidery, and explore the relationship we have with the technology that’s all around us. To that end, there have been plenty of other pieces of functional technology used as art recently as well, but of course this isn’t the first textile computing element to grace these pages.

Thanks to [Thinkerer] for the tip!