Hacking Printed Circuit Board To Create Casing And Instrument Panels

August 9, 2025 by John Elliot V 11 Comments

Over on Hackaday.io our hackers [Angelo] and [Oscarv] are making a replica of the PDP-1. That is interesting in and of itself but the particularly remarkable feature of this project is its novel use of printed circuit boards for casing and instrument panels.

What does that mean in practice? It means creating a KiCad file with a PCB for each side of the case/panel. These pieces can then be ordered from a board house and assembled. In the video below the break you will see an example of putting such a case together. They use sticky tape for scaffolding and then finish things off by soldering the solder joints on each edge together.

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The LumenPnP Pasting Utility: Never Buy Solder Stencils Again?

July 30, 2025 by John Elliot V 11 Comments

Over on his YouTube channel the vivacious [Stephen Hawes] tells us that we never need to buy solder stencils again!

A big claim! And he is quick to admit that his printed solder paste isn’t presently quite as precise as solder stencils, but he is reporting good success with his technique so far.

[Stephen] found that he could print PCBs with his fiber laser, populate his boards with his LumenPnP, and reflow with his oven, but… what about paste? [Stephen] tried making stencils, and in his words: “it sucked!” So he asked himself: what if he didn’t need a stencil? He built a Gerber processing, G-code generating, machine-vision implemented… website. The LumenPnP Pasting Utility: https://paste.opulo.io/

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Transparent PCBs Trigger 90s Nostalgia

July 25, 2025 by Lewin Day 42 Comments

What color do you like your microcontroller boards? Blue? Red? Maybe white or black? Sadly, all of those are about to look old hat. Why? Well, as shared by [JLCPCB], this transparent Arduino looks amazing.

The board house produced this marvel using its transparent flexible printed circuit (FPC) material. Basically, the stuff they use for ribbon cables and flex PCBs, just made slightly differently to be see-through instead of vaguely brown.

The circuit in question is a Flexduino, an Arduino clone specifically designed to work on flexible substrates. It looks particularly good on this transparent material, with the LEDs glowing and the white silkscreen for contrast. If you like what you see, you can order your own circuits using this material directly from JLCPCB’s regular old order form.

Most of all, this project reminds us of the 1990s. Back then, you could get all kinds of games consoles and other electronics with transparent housings. There was the beloved PlayStation Crystal, while Nintendo did something similar with the N64 while adding a whole line of tinted color and charcoal versions too. Somehow seeing a bit of the inside of things is just cool. Even if, in some cases, it’s just to avoid smuggling in prisons.

It took decades before you could get custom PCBs quickly and easily. Now, board houses are competing for the enthusiast (consumer?) market, and competition is spurring development of crazy stuff like transparent and even glow in the dark PCBs. What next? We’re thinking edible, ROHS and WEEE be damned. Drop your thoughts in the comments.

Thanks to [George Graves] for the tip!

Software Defined Retro ROMs

July 19, 2025 by John Elliot V 6 Comments

Here’s something fun from our hacker [Piers]: Software Defined ROMs.

In this series of three videos, [Piers] runs us through what a software defined ROM is, how to make them, and then how to use them.

As [Piers] explains, one frustration a retro technician will face is a failed ROM chip. In the era he’s interested in, there are basically three relevant kinds of ROM chip, all 24-pin Dual Inline Package (DIP):

2364 ROM chip: 8KB; 1x chip-select line
2332 ROM chip: 4KB; 2x chip-select lines
2316 ROM chip: 2KB; 3x chip-select lines

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Screenshot of the cheatsheet being developed in Inkscape

Improve Your KiCad Productivity With These Considered Shortcut Keys

July 17, 2025 by John Elliot V 15 Comments

[Pat Deegan] from Psychogenic Technologies shows us two KiCad tips to save a million clicks, and he made a video to support it, embedded below.

In the same way that it makes sense for you to learn to touch type if you’re going to be using a computer a lot, it makes sense for you to put some thought and effort into your KiCad keyboard shortcuts keys, too.

In this video [Pat] introduces the keymap that he has come up with for the KiCad programs (schematic capture and PCB layout) and explains the rules of thumb that he used to generate his recommended shortcut keys, being:

one handed operation; you should try to make sure that you can operate the keyboard with one hand so your other hand can stay on your mouse
proximity follows frequency; if you use it a lot it should be close to hand
same purpose, same place; across programs similar functions should share the same key
birds of a feather flock together; similar and related functionality kept in proximate clusters
typing trounces topography; if you have to use both hands for typing you have to take your hand off the mouse anyway so then it doesn’t really matter where on the keyboard the shortcut key is

You can find importable KiCad keymaps and customizable SVG cheatsheets in the downloads section.

[Pat]’s video includes some other tips and commentary, but for us the big takeaway was the keymaps. He’s also got a course that you can follow along with for free. And if you haven’t been keeping abreast of developments, KiCad is now at version 9, as of February this year.

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Does Made-in-America Make Sense For PCB Prototyping?

July 6, 2025 by Tyler August 96 Comments

These are tough times for American hackers, and rife with uncertainty. Trade wars are on, off, on again– who can keep track? If you’re used to getting everything from China, that can really cramp your style. [Jeremy Cook] took the time to write up his experience prototyping with American-made PCBs, just in time for us to totally miss Independence Day.

The project was a simple nightlight, using a single LED, a photoresistor, a transistor, and a CR2032 battery. The CR2032 battery does complicate things, though: [Jeremy] figured out a neat way to hold the battery using a PCB cutout, but it needs to be a 0.8 mm board. (That’s going to matter in a moment.) He’s put that PCB on GitHub if you’re interested.

To start off, JLBPCB is the Chinese clearing house of choice for [Jeremy], and they quoted a very cheap $7.10 for 20 boards. The problem was that shipping across the Pacific Ocean, plus the ever-wavering tariff charge, brought the price to $48.08. About five dollars of which was from tariffs; the rest you can put down to the cost of jet fuel and the size of the Pacific Ocean.

On the other hand, OSH Park, was able to get [Jeremy] three of their pretty purple PCBs for $7.75 all-inclusive. Overall, since he’s prototyping and does not want 20 boards this revision, [Jeremy] saves quite a lot by staying local– including the environmental impact of shipping and laxer regulations in China, if that sort of thing matters to you.

The suprizing thing is the turnaround time: [Jeremy] got his pretty purple PCBs from OSH Park a full twenty days after ordering. Similar orders from China take only a week, which is just mind-blowing when you stop and think about the great honking ocean in the way. We could perhaps cut OSH Park some slack in that 0.8 mm boards are not the most common, but their quoted turnaround time for two-layer prototypes is minimum 12 days.

They do offer a “super-swift” option for two-layer boards, but then they lose on price. As [Jeremy] points out, there are always tradeoffs. If you’re really in a hurry, nothing’s faster than milling the boards yourself. Or you could go the old-school toner-transfer etching route.

Our thanks to [Jeremy] for the tip. If you’ve got a better way to prototype, do send us a tip about it. Also, please us know in the comments if you’ve tried an in-country PCB fabricator, and how it compared to the usual offerings from the PRC.

Using an SMD capacitor as a clip for flash media on a circuit board.

SMD Capacitor Doubles As Cheap SD Card Latch

July 4, 2025 by John Elliot V 41 Comments

Here’s a clever hack. Simple, elegant, and eminently cost-effective: using an SMD capacitor to hold your flash media in place!

This is a hack that can pretty much be summed up with just the image at the top of the page — a carefully placed SMD capacitor soldered to a routed tab makes for an extremely cost effective locking mechanism for the nearby SD card slot. There’s just enough flexibility to easily move the capacitor when its time to insert or eject your media.

It’s worth noting that the capacitor in this example doesn’t even appear to be electrically connected to anything. But there’s also no reason you couldn’t position one of the capacitors in your existing bill of materials (BOM). This form of mechanical support will be much cheaper than special purpose clips or mounts. Not a big deal for low-volume projects, but if you’re going high-volume this is definitely something to keep in mind.

If you’re just getting started with SMD capacitors then one of the first things to learn is how to solder them. Also, if you’re hoping to salvage them then try to look for newer equipment which is more likely to have SMD components than through-hole. If you’re planning to use your capacitors for… “capacitance” (how quaint), you can start by learning the basics. And if you want to know everything you can learn about the history of capacitors, too.

Thanks to [JohnU] for writing in to let us know about this one. Have your own natty hacks? Let us know on the tipsline!