Bitten By PCB Defects

May 5, 2015 by Brian Benchoff 54 Comments

If you’ve ordered PCBs from Seeed Studio, ITead, DirtyPCB, or another board house in China, you’ve probably noticed that neat little 100% e-test option available on the order form. If you select this, the board house will throw your PCBs in a machine that will poke a pin in every pad to make sure all the connections are good. Less work for you, right? As [Andy] found out, not always. He was bitten by a manufacturing defect that sheds some light on what that e-test actually is, and the capabilities of what these Chinese board houses can do.

Most of [Andy]’s project have a lot of surface mount components, and when he receives his boards, he notices a few pin pricks on each and every pad. This is from a flying lead machine; a robotic continuity checker that makes sure all the relevant pads are electrically isolated from each other.

One of [Andy]’s recent projects is an entirely through-hole design. Apparently these robotic meters don’t test through-hole pads; it’s significantly harder to measure the continuity of a hole rather than a pad, apparently. After assembling one of these boards, he noticed a problem where one of the GPIOs was permanently high. The offending trace was found underneath a DIP socket, in precisely the worst possible place it could be.

If [Andy] had inspected the board beforehand, this problem would have been avoided. He says it was a relatively simple board with big traces and wide spaces and he didn’t think a manufacturing defect was possible. He was wrong, and now we have a warning. We thank him for that.

The Ultimate Tool For Homebrew PCB Manufacturing

April 26, 2015 by Brian Benchoff 37 Comments

While OSHPark, Seeed Studio, and DirtyPCB have taken most of the fun and urgency out of making your own circuit boards at home, there are still a few niche cases and weird people who like to go it alone. For them, [Jarzębski] has created the ultimate homebrew PCB manufacturing solution (.pl, here’s the Google translatrix).

[Jarzębski] is using UV-sensitive photomasks for his PCBs, but he’s not doing something simple like a blacklight to develop his boards. He’s using a 30 Watt UV LED for exposing his boards. This, of course, generates a lot of heat and to mitigate that he’s added a Peltier cooler, temperature sensor, and a fan to cool off this retina-burning LED. 30 Watts will get the job done, considering [Jarzębski] was using a quartet of 4.5W LEDs before this build.

Developing a PCB is only one part of the equation; you need to etch it, too. For this, [Jarzębski] is using a small 1.6 Liter aquarium and four aquarium heaters for dunking 120mm x 120mm PCBs in the tank. There’s no mention of what chemistry [Jarzębski] is using – ferric chloride, cupric chloride, or otherwise – but the heaters and aerator should make etching go very smoothly.

There’s a video (English) going over the rest of the project below.

Continue reading “The Ultimate Tool For Homebrew PCB Manufacturing” →

$50k In Play: Thirty Projects Will Win Custom PCBs This Week

April 24, 2015 by Mike Szczys 30 Comments

This week we’re giving away $1500 in OSH Park codes to thirty different projects. Submit your project to the 2015 Hackaday Prize now!

$50,000 over the next 17 weeks!

For each of the last four weeks we’ve awarded prize packages to three projects just for submitting ideas. Now it’s time to crank up the rewards. Over the next 17 weeks we will give away $50,000 in prizes. We’re kicking off the week by giving $50 OSH Park codes to 30 different projects.

Of course this is just the tip of the iceberg. This year’s prizes total half a million dollars, with a trip into space for the Grand Prize winner and $100,000 for the Best Product prize. Sitting this one out would be a huge mistake!

You need to post your project on Hackaday.io and officially submit it to the 2015 Hackaday Prize, which means clicking the “Submit-To” button on the left sidebar of your entry (shown below). You can confirm that you’re in the running by looking for the 2015 Hackaday Prize logo on your project gallery picture. Here you can see [castvee8] has submitted the Binary fuel tank, do you think it’s ready for a custom PCB?

To give yourself the best chance at winning, publish a new project log this week that outlines the PCB work your want to do for the entry. We’ll be looking for those as we judge the prizes that are most ready to begin (or advance) their hardware build.

OSH Park offers double-layer boards for $5 per square-inch and you get 3 copies of the board with shipping included. This $50 prize will land you quite a bit of board space. Get started now, you need to have your projects submitted by the morning of Wednesday, April 29th.

The 2015 Hackaday Prize is sponsored by:

A Automated Optical Inspection machine, inspecting the USB Armory board

Meet The Machines That Build Complex PCBs

March 31, 2015 by Eric Evenchick 12 Comments

You can etch a simple PCB at home with a few chemicals and some patience. However, once you get to multilayer boards, you’re going to want to pay someone to do the dirty work.

The folks behind the USB Armory project visited the factories that build their 6 layer PCB and assemble their final product. Then they posted a full walkthrough of the machines used in the manufacturing process.

The boards start out as layers of copper laminates. Each one is etched by applying a film, using a laser to print the design from a Gerber file, and etching away the unwanted copper in a solution. Then the copper and fibreglass prepreg sandwich is bonded together with epoxy and a big press.

Bonded boards then get drilled for vias, run through plating and solder mask processes and finally plated using an Electroless Nickel Immersion Gold (ENIG) process to give them that shiny gold finish. These completed boards are shipped off to another company, where a pick and place followed by reflow soldering mounts all the components to the board. An X-Ray is used to verify that the BGA parts are soldered correctly.

The walkthrough gives a detailed explanation of the process. It shows us the machines that create products we rely on daily, but never get to see.

Inexpensively Replace A Worn Out N64 Joystick

March 27, 2015 by Bryan Cockfield 6 Comments

The Nintendo 64 is certainly a classic video game system, with amazing titles like Mario Kart 64 and Super Smash Bros that are still being played across the world today. But, like finding new parts for a classic car, finding an original controller that doesn’t have a sad, wobbly, worn-out joystick is getting to be quite the task. A common solution to this problem is to replace the joystick with one from a Gamecube controller, but the kits to do this are about $20USD, and if that’s too expensive then [Frenetic Rapport] has instructions for doing this hack for about $2.

The first iteration of using a Gamecube stick on an N64 controller was a little haphazard. The sensitivity was off and the timing wasn’t exactly right (very important for Smash Bros.) but the first kit solved these problems. This was the $20 kit that basically had a newer PCB/microcontroller that handled the Gamecube hardware better. The improvement which drove the costs down to $2 involves modifying the original PCB directly rather than replacing it.

While this solution does decrease the cost, it sacrifices the new potentiometer and some of the easier-to-work-with jumpers, but what was also driving this project (in addition to cost) was the fact that the new PCBs were becoming harder to get. It essentially became more feasible to simply modify the existing hardware than to try to source one of the new parts.

Either way you want to go, it’s now very easy to pwn your friends in Smash with a superior controller, rather than using a borked N64 controller you’ve had for 15 years. It’s also great to see hacks like this that come together through necessity and really get into the meat of the hardware. Perhaps we’ll see this controller ported to work with other versions of Super Smash Bros, too!

Hands-On Othermill Review Grinds Out Sparkling Results

March 27, 2015 by Mike Szczys 44 Comments

We’ve been on the lookout for alternatives to chemically etching circuit boards for years. The problem has been that we don’t particularly want to devote months of or lives learning how to build precision CNC mills. Off in the distance there may be an answer for that quandary if you don’t mind parting with twenty-two Benjamins. Sure, it’s a heck of a lot more expensive than toner transfer and cupric chloride, but the Othermill can be purchased right now (in your hands a few months later) and after reading this in-depth review we are a bit less hesitant about opening our wallets for it.

It’s a tome of a review, but that means there’s something for everybody. We especially enjoyed seeing the 10 mil board shown here which took about 1-hour to mill. Considering it has also been through-hole drilled we’d put that on part with the time it takes to etch a board. There are obvious places where the traces are not perfectly smooth (not sure if that’s burring or over-milling) but they are not broken and the board’s ready to be populated.

Alignment is something of an issue, but the Othermill isn’t limited to PCBs so we’d recommend designing and milling your own alignment bracket system as an early project.

Who isn’t envious of custom-builds that can get down to 10-mils, like this beauty from 2013. Our hopes had been sparked when Carbide 3D came onto the scene. We’re still optimistic that they will make a big splash when they start shipping preorders in a few months.

As this review proves, Othermill is already out in the wild with a 6-8 week wait before shipping. We saw it in action milling multiple materials at the Hackaday Omnibus Lauch Party and were duly impressed. Price or waiting-period aside we’re going to hold off until the software options expand beyond Mac-only (UPDATE: Othermill software support for Windows was added in early 2016); either Othermill will add support or someone will come up with a hack to use traditional CNC software. But if you count yourself as a subscriber to the cult of Apple the software, called Otherplan, does get a favorable prognosis along with the hardware.

Already have an Othermill sitting on your bench? Let us know your what you think about it in the comments below.

Bonus content: [Mike Estee], CTO of Othermill just gave a talk last night about how he got into making mills and the challenges of building something with super-high-precision. Sound isn’t good but the talk is solid. Hackaday’s [Joshua Vasquez] also gives a talk on the video about building an SPI core for FPGA. These talks are one of the Hardware Developer’s Didactic Galactic series which you really should check out if you’re ever in the San Francisco area.

Continue reading “Hands-On Othermill Review Grinds Out Sparkling Results” →

Open Source Binary Wristwatch Is Professional Quality

March 8, 2015 by Rick Osgood 29 Comments

If you want to proclaim to the world that you’re a geek, one good way to go about it is to wear a wristwatch that displays the time in binary. [Jordan] designs embedded systems, and he figured that by building this watch he could not only build up his geek cred but also learn a thing or two about working with PIC microcontrollers for low power applications. It seems he was able to accomplish both of these goals.

The wristwatch runs off of a PIC18F24J11 microcontroller. This chip seemed ideal because it included a built in real-time clock and calendar source. It also included enough pins to drive the LEDs without the need of a shift register. The icing on the cake was a deep sleep mode that would decrease the overall power consumption.

The watch contains three sets of LEDs to display the information. Two green LEDs get toggled back and forth to indicate to the user whether the time or date is being displayed. When the time is being displayed, the green LED toggles on or off each second. The top row of red LEDs displays either the current hour or month. The bottom row of blue LEDs displays the minutes or the day of the month. The PCB silk screen has labels that help the user identify what each LED is for.

The unit is controlled via two push buttons. The three primary modes are time, date, and seconds. “Seconds” mode changes the bottom row of LEDs so they update to show how many seconds have passed in the current minute. [Jordan] went so far as to include a sort of animation in between modes. Whenever the mode is changed, the LED values shift in from the left. Small things like that really take this project a step further than most.

The board includes a header to make it easy to reprogram the PIC. [Jordan] seized an opportunity to make extra use out of this header. By placing the header at the top of the board, and an extra header at the bottom, he was able to use a ribbon cable as the watch band. The cable is not used in normal operation, but it adds that extra bit of geekiness to an already geeky project.

[Jordan] got such a big response from the Internet community about this project that he started selling them online. The only problem is he sold out immediately. Luckily for us, he released all of the source code and schematics on GitHub so we can make our own.