CNC Turns a Single PCB into Origami Hemisphere

Trying to make a hemispherical surface out of a PCB is no easy feat. Trying to do that and make the result a working circuit is even harder. Doing it with one solid piece of FR4 seems impossible, right?

Not so much. [brainsmoke] came up with a clever way to make foldable, working PCBs that can be formed into hemispheres. The inspiration for this came from a larger project that resulted in a 32-cm diameter LED-studded sphere, which a friend thought would make a swell necklace if it was scaled down. That larger sphere was made somewhat like a PCB soccer ball, with individual panels soldered together. [brainsmoke] didn’t relish juggling dozens of tiny PCBs to make a necklace-sized version, so the unfolded pattern for half a deltoidal hexecontahedron was laid out as one piece on single-sided FR4. The etched boards were then cut out on a CNC mill, with the joints between the panels cut as V-grooves from the rear of the board. By leaving just enough material to act as a live hinge, [brainsmoke] was able to fold the pattern up into a hemisphere while leaving the traces intact. The process was fussy and resulted in a lot of broken FR4 and traces, but with practice and the use of thicker board material and heavier copper, the hemisphere came together. The video below shows the final product

This objet d’art is [brainsmoke]’s entry in the Circuit Sculpture Contest, which is just wrapping up wrapped up last week. We can’t wait to share some of the cool things people came up with in this contest, which really seemed to get the creative juices flowing.

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An Awesome Open Mechanical Keyboard

Who doesn’t want a little added functionality to their  lives? Feeling a few shortcut keys would make working in Eagle a bit smoother, [dekuNukem] built his own programmable mechanical keypad: kbord.

It sports vibrant RGB LED backlight effects with different animations, 15 keys that execute scripts — anything from ctrl+c to backdoors — or simple keystrokes, up to 32 profiles, and a small OLED screen to keep track of which key does what!

kbord is using a STM32F072C8T6 microcontroller for its cost, speed, pins, and peripherals, Gateron RGB mechanical keys — but any clear key and keycaps with an opening for the kbord’s LEDs will do — on a light-diffusing switch plate, and SK6812 LEDs for a slick aesthetic.

Check out the timelapse video tour of his build process after the break! (Slightly NSFW, adolescent humor for a few seconds of the otherwise very cool video. Such is life.)

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WS2812B LED Clones: Work Better Than Originals!

Commodity electronics manufacturing is a tough game. If you come out with a world-beating product, like WorldSemi did with the WS2812B addressable RGB LED “pixel”, you can be pretty sure that you’re going to be cloned in fairly short order. And we’re all used to horror stories of being sold clones instead of what was ordered. But what if the clones were actually an improvement?

[Gonazar] bought some strips of “WS2812” LEDs and prototyped a project. When stepping up to larger production, he thought he’d go directly to WorldSemi. Long story short, the cheaper LED modules that he’d previously bought weren’t from WorldSemi, but were actually SK6812 clones labelled as WS2812Bs. When he switched to the real thing, he discovered that they had some temperature and pressure sensitivities that the clones didn’t. The clones were better!

They weren’t even straight clones. It turns out that they have a much higher PWM frequency, resulting in less flicker at low brightnesses. The distributor came clean, saying that they swapped them out without note because they spoke the same protocol, but were a strict improvement.

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