Blast Away The Flux — With Brake Cleaner?

December 26, 2024 by Dan Maloney 74 Comments

Can you use brake cleaner for flux removal on PCBs? According to [Half Burnt Toast], yes you can. But should you? Well, that’s another matter.

In our experience, flux removal seems to be far more difficult than it should be. We’ve seen plenty of examples of a tiny drop of isopropyl alcohol and a bit of light agitation with a cotton swab being more than enough to loosen up even the nastiest baked-on flux. If we do the same thing, all we get is a gummy mess embedded with cotton fibers smeared all over the board. We might be doing something wrong, or perhaps using the wrong flux, but every time we get those results, we have to admit toying with the idea of more extreme measures.

The LED bar graphs were not a fan of the brake cleaner.

[Toast] went there, busting out a fresh can of brake cleaner and hosing down some of the crustier examples in his collection. The heady dry-cleaner aroma of perchloroethylene was soon in the air, and the powerful solvent along with the high-pressure aerosol blast seemed to work wonders on flux. The board substrate, the resist layer, and the silkscreen all seemed unaffected by the solvent, and the components were left mostly intact; one LED bar graph display did a little melty, though.

So it works, but you might want to think twice about it. The chlorinated formula he used for these tests is pretty strong stuff, and isn’t even available in a lot of places. Ironically, the more environmentally friendly stuff seems like it would be even worse, loaded as it is with acetone and toluene. Whichever formula you choose, proceed with caution and use the appropriate PPE.

What even is flux, and what makes it so hard to clean? Making your own might provide some answers.

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Dog Poop Drone Cleans Up The Yard So You Don’t Have To

September 28, 2024 by Dan Maloney 20 Comments

Sometimes you instantly know who’s behind a project from the subject matter alone. So when we saw this “aerial dog poop removal system” show up in the tips line, we knew it had to be the work of [Caleb Olson].

If you’re unfamiliar with [Caleb]’s oeuvre, let us refresh your memory. [Caleb] has been on a bit of a dog poop journey, starting with a machine-learning system that analyzed security camera footage to detect when the adorable [Twinkie] dropped a deuce in the yard. Not content with just knowing when a poop event has occurred, he automated the task of locating the packages with a poop-pointing robot laser. Removal of the poop remained a manual task, one which [Caleb] was keen to outsource, hence the current work.

The video below, from a lightning talk at a conference, is pretty much all we have to go on, and the quality is a bit potato-esque. And while [Caleb]’s PoopCopter is clearly still a prototype, it’s easy to get the gist. Combining data from the previous poop-adjacent efforts, [Caleb] has built a quadcopter that can (or will, someday) be guided to the approximate location of the offending package, home in on it using a downward-looking camera, and autonomously whisk it away.

The retrieval mechanism is the high point for us; rather than a complicated, servo-laden “sky scoop” or something similar, the drone has a bell-shaped container on its belly with a series of geared leaves on the open end. The leaves are open when the drone descends onto the payload, and then close as the drone does a quick rotation around the yaw axis. And, as [Caleb] gleefully notes, the leaves can also open in midair with a high-torque yaw move in the opposite direction; the potential for neighborly hijinx is staggering.

All jokes and puns aside, this looks fantastic, and we can’t wait for more information and a better video. And lest you think [Caleb] only works on “Number Two” problems, never fear — he’s also put considerable work into automating his offspring and taking the awkwardness out of social interactions.

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Remove Wall Plugs Fast With A Custom Tool

April 18, 2024 by Lewin Day 39 Comments

The best thing about buying your own home is that you can hang things on the walls. It’s a human right all too often denied to renters the world over. Regardless, five years later, when you’re doing the mandatory minimalist remodel, you’ll be ruing the day you put in all those wall anchors. At that point, consider removing them with this nifty tool from [XDIY with Itzik].

The design aims to remove wall anchors as cleanly as possible. It’s easiest to watch the video to get the idea of how it works.

The tool features a block which holds a bearing. That bearing acts as a rotating stop for a wood screw. The idea is that you place the block against the wall, and use a power drill to drive a wood screw into the anchor at high speed. The screw can’t move forward, so the threads basically yank the plug out of the wall, and relatively neatly at that. Once removed, there’s a little push stopper you can use to hold the old plug in place as you remove the wood screw from the device, ready to go again.

[Itzik] demonstrates the device by removing ten wall plugs in just 40 seconds. If you’ve got a lot to do, or it’s a job you do regularly, you might like to have this tool in your kit.

Oftentimes, having the right tool can make a job ten times faster, and this seems like one of those cases. Video after the break.

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How Safe Is That Ultrasonic Bath For Flux Removal?

December 5, 2019 by Dan Maloney 30 Comments

How do you clean the residual flux off your boards? There are plenty of ways to go about the job, ranging from “why bother?” to the careful application of isopropyl alcohol to every joint with a cotton swab. It seems like more and more people are turning to ultrasonic cleaners to get the job done, though, and for good reason: just dunk your board and walk away while cavitation does the work for you.

But just how safe is it to sonically blast the flux off your boards? [SDG Electronics] wanted to know, so he ran some cleaning tests to get to the bottom of things. On the face of it, dunking a PCB in an aqueous cleaning solution seems ill-advised; after all, water and electricity famously don’t mix. But assuming all the nooks and crannies of a board can be dried out before power is applied, the cleaning solution itself should be of little concern. The main beef with ultrasonic cleaning seems to be with the acoustic energy coupling with mechanical systems on boards, such as crystal oscillators or micro-electrical-mechanical systems (MEMS) components, such as accelerometers or microphones. Such components could resonate with the ultrasonic waves and be blasted to bits internally.

To test this, [SDG Electronics] built a board with various potentially vulnerable components, including the popular 32.768-kHz crystal, cut for a frequency quite close to the cleaner’s fundamental. The video below goes into some detail on the before-and-after tests, but the short story is that nothing untoward happened to any of the test circuits. Granted, no components with openings as you might find on some MEMS microphones were tested, so be careful. After all, we know that ultrasound can deal damage, and if it can levitate tiny styrofoam balls, it might just do your circuit in.

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