Solder Ninja Dabbles In USB Power Arcana

September 9, 2019 by Lewin Day 22 Comments

USB first hit the scene in the 1990s, and was intended to simplify connecting peripherals to PCs and eliminate the proliferation of various legacy interfaces. Over 20 years later, it’s not only achieved its initial goals, but become a de facto standard for charging and power supply for all manner of personal electronic gadgets. If you asked someone back in 1995 whether or not you could build a USB-powered soldering iron, they’d have politely asked you to leave the USB Implementers Forum. But times change, and Solder Ninja is just that!

With a maximum power draw of 40 W, the Solder Ninja required careful design to ensure practicality. It supports a variety of USB power standards, including USB-BC 1.2, USB Quick Charge, and USB Power Delivery. This enables it to draw the large amounts of current required for the heating element. To make it easy to use with a variety of chargers out in the wild, it displays the current negotiated voltage and maximum current draw. This enables the user to understand the varying performance of the device, depending on the charger it’s plugged into.

Given the multitude of different USB power standards, we imagine [Nicolas] has the patience of a saint to perfect a project like this. We’ve seen similar builds before, too. Video after the break.

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Field Expedient Soldering Iron Will Do In A Pinch

August 8, 2019 by Al Williams 16 Comments

If you think [Dubious Engineering]’s moniker is just a name, have a look at the pretty terrible soldering iron hacked out of a lighter in the video below. No one is suggesting this is a good idea but in an emergency, maybe it would come in handy. We liked the use of a chopstick and the formation of a heat exchanger with the copper wire coil. It was a mild disappointment that you had to drill out the chopstick, but we think you could have figured out a different method with a little thought.

The use of duct tape, of course, lends it instant hacker credibility. We suppose this might be useful not just after the robot uprising, but if you had to make a few quick solder joints far away from power and you don’t have a battery-operated iron.

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A USB -C Soldering Iron For Weller Tips

April 19, 2019 by Jenny List 5 Comments

There was a time when a decent temperature controlled soldering iron took the form of the iron itself and a box of electronics, but now it’s just as likely to be a miniaturised affair with the temperature controller built into a slim and lightweight handle. Irons such as the Miniware TS series have become firm favourites, displacing a traditional soldering station for many.

[Thomas.lepi] has combined the best of both worlds, with a TS-style microprocessor-driven handle driving the familiar Weller RT elements. Its interface is very simple, but through its USB power socket a serial port provides opportunities for adjustment. Providing control is an STM32F042G6U6 ARM Cortex M0 microcontroller, with USB power control coming from an STUSB4500QTR .

If you are used to irons such as the Miniware TS100 then this one with its smartly 3D-printed case will be very straightforward to use. Whether or not the ready availability of the TS100 or its USB-C sibling would remove the need to build this iron is up to you, but then again that’s hardly the point. The Weller tips are some of the better ones of their type, so perhaps that might make this project worth a second look.

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The Solderdoodle Open Source Iron Rides Again

January 3, 2019 by Tom Nardi 25 Comments

Over the last year or so, cordless portable soldering irons have become all the rage. In fact, at this point a good number of Hackaday readers out there have likely traded in their full-size AC irons for a DC iron that’s only slightly larger than a pen. But before the big boom in portable irons, in the ye olden days of 2014, we brought you word of the open source Solderdoodle created by [Isaac Porras]. Based upon the Weller BP645 and featuring a 3D printed case, the DIY iron was designed to be charged from a standard USB port.

Now, [Isaac] is back with an updated version he calls the Solderdoodle Plus. It’s still based on the heating element from the Weller BP645, but now boasts twice the power, an improved 3D printed case, an intuitive touch-based user interface, and even some LED blinkenlights for good measure. As with the original Solderdoodle the hardware and software for the device are open source and you’re invited to build your own, though kits are also available through an already fully-funded Kickstarter campaign.

[Isaac] says that the temperature control functions on traditional corded soldering irons waste energy due to the large thermal mass they have to bring up to temperature. But with less thermal mass and a system of variable duty cycle pulsed power, he says the Solderdoodle Plus can do the same work as an old-school 60 watt iron while only consuming 10 watts. This allows the iron to maintain a constant 500°C for over an hour on the dual internal Panasonic NCR18500A lithium-ion batteries, and means you can charge it up with nothing more exotic than a micro USB cable.

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DIY Arduino Soldering Iron Hits Version 2.0

September 22, 2018 by Tom Nardi 11 Comments

A few months ago we brought word that [Electronoobs] was working on his own open source alternative to pocket-sized temperature controlled soldering irons like the TS100. Powered by the ATMega328p microcontroller and utilizing a 3D printed enclosure, his version could be built for as little as $15 USD depending on where you sourced your parts from. But by his own admission, the design was held back by the quality of the $5 replacement soldering iron tips he designed it around. As the saying goes, you get what you pay for.

But [Electronoobs] is back with the second version of his DIY portable soldering iron, and this time it’s using the vastly superior HAKKO T12 style tip. As this tip has the thermocouple and heating element in series it involved a fairly extensive redesign of the entire project, but in the end it’s worth it. After all, a soldering iron is really only as good as its tip to begin with.

This version of the iron deletes the MAX6675 used in V1, and replaces it with a LM358 operational amplifier to read the thermocouple in the T12 tip. [Electronoobs] then used an external thermocouple to compare the LM358’s output to the actual temperature at the tip. With this data he created a function which will return tip temperature from the analog voltage.

While the physical and electrical elements of the tip changed substantially, a lot of the design is still the same from the first version. In addition to the ATMega328p microcontroller, version 2.0 of the iron still uses the same 128×32 I2C OLED display, MOSFET, and 5V buck converter from the original iron. That said, [Electronoobs] is already considering a third revision that will make the iron even smaller by replacing the MOSFET and buck converter. It might be best to consider this an intermediate step before the DIY iron takes on its final form, which we’re very interested in seeing.

The first version of the DIY Arduino soldering iron garnered quite a bit of attention, so it seems there’s a decent number of you out there who aren’t content with just plunking down the cash for the TS100.

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Spot Welding …Plastic?

August 5, 2018 by Ben James 12 Comments

Plastic milk bottles, when your project or prototype needs an urgent source of plastic, they are often the first thing to hand. Convenient and flexible, but strong at the same time and usually free, they’re the ultimate source of material in a pinch. However, when it comes to actually manipulating the HDPE plastic they’re made from, there’s often a challenge. It’s easy to cut, but not so easy to join. Conventional glues can have a hard time, making it difficult to bond.

Enter [zimitt], and a spot welding solution for joining HDPE with ease. Ok, so ‘spot welding’ might be a little optimistic given the speed of this process, but it’s useful nonetheless. To heat the plastic, a cheap soldering iron is recommended. A low wattage, straight-to-the-wall one does well, especially as they commonly have the washer-style end shown in the picture. To protect the plastic from burning, a BBQ mat is used – they’re temperature resistant and usually made with a PTFE surface.

First, place the two sheets of plastic face to face and sandwich top and bottom with the BBQ mat. Apply some heat to the mat with the soldering iron then, after a few seconds, remove the iron and provide pressure with a flat object to bond the plastic. [zimitt] used an espresso tamper for this which was ideal.

The results are impressive, and [zimitt] experiments with different plastics as well. Of course, you should exercise caution when attempting anything like this, given the health risks present when heating up different types of plastic.

HDPE is easy to recycle at home, and we’ve seen a lot of great uses: a plastic joiner’s mallet, plastic tiles, and even a filament extruder for 3D printing.

Build Your Own Portable Arduino Soldering Iron

July 9, 2018 by Tom Nardi 42 Comments

At this point you’ve almost certainly seen one of these low-cost portable soldering irons, perhaps best exemplified by the TS100, a pocket-sized temperature controlled iron that can be had for as little as $50 USD from the usual overseas suppliers. Whether or not you’re personally a fan of the portable irons compared to a soldering station, the fact remains that these small irons are becoming increasingly popular with hackers and makers that are operating on a budget or in a small workspace.

Believing that imitation is the most sincere form of flattery, [Electronoobs] has come up with a DIY portable soldering iron that the adventurous hacker can build themselves. Powered by an ATMega328p pulled out of an Arduino Nano, if offers the same software customization options of the TS100 but at a considerably lower price. Depending on where you source your components, you should be able to build one of these irons for as little as $15.

The iron features a custom PCB and MAX6675 thermocouple amplifier to measure tip temperature. A basic user interface is provided by two tactile buttons on the PCB as well as an 128×32 I2C OLED display. In a future version, [Electronoobs] says he will look into adding some kind of sensor to detect when the iron is actually being used and put it to sleep when inactive.

The tip is sourced from a cheap soldering station replacement iron, and according to [Electronoobs], is probably the weakest element of the entire build. He’s looking into using replacement TS100 tips, but says he’ll need to redesign his electronics to make it compatible. The case is a simple 3D printed affair, which looks solid enough, but seems likely to be streamlined in later versions.

We’ve seen a number of attempts at DIY soldering irons over the years, but we have to say, this one is probably the most professional we’ve ever seen. It will be interesting to see how future revisions improve on this already strong initial showing.

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