The PCB Router You Wish You Had Made

June 14, 2025 by Jenny List 39 Comments

The advent of cheap and accessible one-off PCB production has been one of the pivotal moments for electronic experimenters during the last couple of decades. Perhaps a few still etch their own boards, but many hobbiest were happy to put away their ferric chloride. There’s another way to make PCBs, though, which is to mill them. [Tom Nixon] has made a small CNC mill for that purpose, and it’s rather beautiful.

In operation it’s a conventional XYZ mechanism, with a belt drive for the X and Y and a lead screw for the Z axis. The frame is made from aluminium extrusion, and the incidental parts such as the belt tensioners are 3D printed. The write-up is very comprehensive, and takes the reader through all the stages of construction. The brains of the outfit is a Creality 3D printer controller, but he acknowledges that it’s not the best for the job.

It’s certainly not the first PCB router we’ve seen, but it may be one of the nicer ones. If you make a PCB this way, you might like to give it professional-looking solder mask with a laser.

Open Source CAD In The Browser

June 12, 2025 by Al Williams 43 Comments

Some people love tools in their browsers. Others hate them. We certainly do like to see just how far people can push the browser and version 0.6 of CHILI3D, a browser-based CAD program, certainly pushes.

If you click the link, you might want to find the top right corner to change the language (although a few messages stubbornly refuse to use English). From there, click New Document and you’ll see an impressive slate of features in the menus and toolbars.

The export button is one of those stubborn features. If you draw something and select export, you’ll see a dialog in Chinese. Translated it has the title: Select and a checkmark for “Determined” and a red X for “Cancelled.” If you select some things in the drawing and click the green checkmark, it will export a brep file. That file format is common with CAD programs, but you’ll need to convert, probably, if you want to 3D print your design.

The project’s GitHub repository shows an impressive slate of features, but also notes that things are changing as this is alpha software. The CAD kernel is a common one brought in via WebAssembly, so there shouldn’t be many simple bugs involving geometry.

We’ve seen a number of browser-based tools that do some kind of CAD. CADmium is a recent entry into the list. Or, stick with OpenSCAD. We sometimes go low-tech for schematics.

Supercon 2024: Sketching With Machines

April 28, 2025 by Lewin Day 2 Comments

When it comes to our machines, we generally have very prescribed and ordered ways of working with them. We know how to tune our CNC mill for the minimum chatter when its chewing through aluminium. We know how to get our FDM printer to lay perfect, neat layers to minimize the defects in our 3D prints.

That’s not what Blair Subbaraman came down to talk about at the 2024 Hackaday Supercon, though. Instead, Blair’s talk covered the magic that happens when you work outside the built-in assumptions and get creative. It’s all about sketching with machines.

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DIY Record Cutting Lathe Is Really Groovy

April 22, 2025 by Tyler August 12 Comments

Back in the day, one of the few reasons to prefer compact cassette tape to vinyl was the fact you could record it at home in very good fidelity. Sure, if you had the scratch, you could go out and get a small batch of records made from that tape, but the machinery to do it was expensive and not always easy to come by, depending where you lived. That goes double today, but we’re in the middle of a vinyl renaissance! [ronald] wanted to make records, but was unable to find a lathe, so decided to take matters into his own hands, and build his own vinyl record cutting lathe.

photograph of [ronald's] setup — [ronald’s] record cutting lathe looks quite professional.

It seems like it should be a simple problem, at least in concept: wiggle an engraving needle to scratch grooves in plastic. Of course for a stereo record, the wiggling needs to be two-axis, and for stereo HiFi you need that wiggling to be very precise over a very large range of frequencies (7 Hz to 50 kHz, to match the pros). Then of course there’s the question of how you’re controlling the wiggling of this engraving needle. (In this case, it’s through a DAC, so technically this is a CNC hack.) As often happens, once you get down to brass tacks (or diamond styluses, as the case may be) the “simple” problem becomes a major project. Continue reading →

An attractive orange CNC mill sitting ona bench.

3D Printed Milling Machine Is Solid As A Rock

April 13, 2025 by Tyler August 59 Comments

There are no shortage of CNC machines in the DIY space these days, but sometimes you just need to do things your own way. That’s what [Chris Borges] decided when he put together this rock-solid, concrete-filled CNC milling machine.

The concrete body of this machine is housed inside a 3D printed shell, which makes for an attractive skin as well as a handy mold. Within the concrete is a steel skeleton, with the ‘rebar’ being made of threaded rods and a length of square tubing to hold the main column. You can see the concrete being poured in around the rebar in the image, or watch it happen in the build video embedded below.

An image of the main column of [Chris]'s CNC mill as the concrete is added. The steel reinforcement is clearly visible. — In goes the concrete, up goes the rigidity.

All three axes slide on linear rails, and are attached to lead screws driven by the omnipresent NEMA 17 steppers. The air-cooled spindle, apparently the weak-point of the design, is attached to a pivoting counterweight, but make no mistake: it is on rails. All-in-all, it looks like a very rigid, and very capable design — [Chris] shows it cutting through aluminum quite nicely.

Given that [Chris] has apparently never used a true mill before, this design came out remarkably well. Between the Bill of Materials and 45 page step-by-step assembly instructions, he’s also done a fantastic job documenting the build for anyone who wants to put one together for themselves.

This isn’t the first concrete-filled project we’ve highlighted from [Chris], you may remember seeing his lathe on these pages. It certainly isn’t the first CNC mill we’ve covered, either.

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Your Badminton Racket Needs Restringing? There’s A DIY Machine For That

March 27, 2025 by Elliot Williams 4 Comments

We don’t often get our badminton rackets restrung, but if we did, [kuokuo702]’s PicoBETH project would be where we’d turn. This is a neat machine build for a very niche application, but it’s also a nicely elaborated project with motors, load cells, and even a sweet knobby-patterned faceplate that is certainly worth a look even if you’re not doing your own restringing.

We’ll admit that everything we know about restringing rackets we learned by watching [kuokuo]’s demo video, but the basic procedure goes like this: you zigzag the string through the holes in the racket, controlling the tension at each stage along the way. A professional racket frame and clamp hold the tension constant while you fiddle the string through the next hole, but getting the tension just right in the first place is the job of [kuokuo]’s machine. It does this with a load cell, stepper motor, and ball screw, all under microcontroller control. Pull the string through, let the machine tension it, clamp it down, and then move on to the next row.

Automating the tension head allows [kuokuo] to do some fancy tricks, like pre-stretching the strings and even logging the tension in the string at each step along the way. The firmware has an extensive self-calibration procedure, and in all seems to be very professional. But it’s not simply functional; it also has a fun LEGO-compatible collection of bumps integrated into the 3D-printed dust cover. That way, your minifigs can watch you at work? Why not!

Automating random chores is a great excuse to build fun little machines, and in that vein, we salute [kuokuo]’s endeavor. Once you start, you’ll find stepper motors sprouting all around like crocuses in a spring field. And speaking of spring, Easter is just around the corner. So if you don’t play badminton, maybe it’s time to build yourself an eggbot.

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Mural: The Plotter That Draws On Walls

March 24, 2025 by Lewin Day 15 Comments

Let’s say you’ve got a big bare wall in your home, and you want some art on it. You could hang a poster or a framed artwork, or you could learn to paint a mural yourself. Or, like [Nik Ivanov], you could build a plotter called Mural, and get it to draw something on the wall for you.

The build is straightforward enough. It uses a moving carriage suspended from toothed belts attached to two points up high on the wall. Stepper motors built into the carriage reel the belts in and out to move it up and down the wall, and from side to side. In this case, [Nik] selected a pair of NEMA 17 steppers to do the job. They’re commanded by a NodeMCU ESP32, paired with TMC2209 stepper motor drivers. The carriage also includes a pen lifter, which relies on a MG90s servo to lift the drawing implement away from the wall.

The build is quite capable, able to recreate SVG vector graphics quite accurately, without obvious skew or distortion. [Nik] has been using the plotter with washable Crayola markers, so he can print on the wall time and again without leaving permanent marks. It’s a great way to decorate—over and over again—on a budget. Total estimated cost is under $100, according to [Nik].

We’ve featured some neat projects along these lines before, too. Video after the break.

Continue reading “Mural: The Plotter That Draws On Walls” →