PCB Hacks

128 Articles

Production KiCad Template Covers All Your Bases

December 10, 2025 by 8 Comments

Ever think about all the moving parts involving a big KiCad project going into production? You need to provide manufacturer documentation, assembly instructions and renders for them to reference, every output file they could want, and all of it has to always stay up to date. [Vincent Nguyen] has a software pipeline to create all the files and documentation you could ever want upon release – with an extensive installation and usage guide, helping you turn your KiCad projects truly production-grade.

This KiBot-based project template has no shortage of features. It generates assembly documents with custom processing for a number of production scenarios like DNPs, stackup and drill tables, fab notes, it adds features like table of contents and 3D renders into KiCad-produced documents as compared to KiCad’s spartan defaults, and it autogenerates all the outputs you could want – from Gerbers, .step and BOM files, to ERC/DRC reports and visual diffs.

This pipeline is Github-tailored, but it can also be run locally, and it works wonderfully for those moments when you need to release a PCB into the wild, while making sure that the least amount of things possible can go wrong during production. With all the features, it might take a bit to get used to. Don’t need fully-featured, just some GitHub page images? Use this simple plugin to auto-add render images in your KiCad repositories, then.

Continue reading “Production KiCad Template Covers All Your Bases” →

PCB Design Review: TinySparrow, A Module For CAN Hacking, V2

December 9, 2025 by 12 Comments

A year ago, I’ve design reviewed an MCU module for CAN hacking, called TinySparrow. Modules are plenty cool, and even more so when they’re intended for remaking car ECUs. For a while now, every car has heavily depended on a computer to control the operation of everything inside it – the engine and its infrastructure, the lights, and  Sadly, ECUs are quite non-hackable, so building your own ECUs only makes sense – which is why it’s heartwarming to see modules intended to make this easier on the budding ECU designer!

Last time we saw this module, it was quite a bit simpler. We talked about fixing a number of things – the linear regulator, the unprotected CAN transceiver, and the pinout; we also made the board cheaper to produce by reducing the layer count and instead pushing the clearance/track width limits. This time, we’re seeing TinySparrow v2 , redesigned accounting for the feedback and upgraded with a new MCU – it’s quite a bit more powerful!

For a start, it’s got ESD diodes, a switching-linear regulator chain for clean but efficient power supply, and most importantly, an upgraded MCU, now with USB and one more CAN channel for a total of two! There’s a lot more GPIOs to go around, too, so the PCB now uses all four of its sides for breakout out power, programming, and GPIO pads. Only a tiny bit bigger than its v1, this module packs a fair bit of punch.

Let’s revisit the design, and try to find anything still left to improve – there’s a few noteworthy things I found.

Continue reading “PCB Design Review: TinySparrow, A Module For CAN Hacking, V2” →

An Online Repository For KiCad Schematics

November 28, 2025 by 26 Comments

In the desktop 3D printing world, we’re fortunate to have multiple online repositories of models that anyone can load up on their machine. Looking to create a similar experience but for electronic projects, [Mike Ayles] created CircuitSnips — a searchable database of ready-to-use KiCad schematics available under open source licenses.

Looking for reference designs for LiPo chargers? CircuitSnips has you covered. Want to upload your own design so others can utilize it? Even better. Currently, there are over four thousand circuits on CircuitSnips, although not all have been put there purposely. To get the project off the ground, [Mike] scraped GitHub for open source KiCad projects. While this doesn’t run afoul of the licensing, there’s a mechanism in place for anyone who wants to have their project removed from  the repository.

To scrape the depths of GitHub, [Mike] had to simplify the text expression for the KiCad projects using a tool he’s since released. For anyone so inclined, he’s even put the entire site on GitHub for anyone who wants to try their hand at running it locally.

CircuitSnaps fills a very specific space to post your circuit diagrams, but if you’re looking for somewhere to host your complete designs, we can’t fail to mention Hackaday’s own repository for hardware projects and hacks!

KiDoom Brings Classic Shooter To KiCad

November 26, 2025 by 8 Comments

As the saying goes: if it has a processor and a display, it can run DOOM. The corollary here is that if some software displays things, someone will figure out a way to make it render the iconic shooter. Case in point KiDoom by [Mike Ayles], which happily renders DOOM in KiCad at a sedate 10 to 25 frames per second as you blast away at your PCB routing demons.

Obviously, the game isn’t running directly in KiCad, but it does use the doomgeneric DOOM engine in a separate process, with KiCad’s PCB editor handling the rendering. As noted by [Mike], he could have used a Python version of DOOM to target KiCad’s Python API, but that’s left as an exercise for the reader.

Rather than having the engine render directly to a display, [Mike] wrote code to extract the position of sprites and wall segments, which is then sent to KiCad via its Python interface, updating the view and refreshing the ‘PCB’. Controls are as usual, though you’ll be looking at QFP-64 package footprints for enemies, SOIC-8 for decorations and SOT-23-3 packages for health, ammo and keys.

If you’re itching to give it a try, the GitHub project can be found right here. Maybe it’ll bring some relief after a particularly frustrating PCB routing session.

Styrofoam watercraft, PCB hydrofoil

A PCB Can Be A Hydrofoil, If It Really Wants To

November 23, 2025 by 10 Comments

You know those old cliche that the younger generations have begun to cynically despise: “follow your dreams!” “You can be anything you put your mind to!” — well, perhaps they are true on occasion. For instance when [rctestflight] had PCBs that dreamed of becoming a hydrofoil, he found a way to make that dream come true.

It’s kind of obvious in retrospect: printed circuit boards are made of FR4, which is a form of fiberglass, and you know what else is commonly made of fiberglass? Boats. So yes, the material is suited for this task. The fact that solder joints hold up to use in a little remote-control hydrofoil is less obvious, but good to know. It certainly makes for easier assembly for those of us who have developed an allergy to epoxy.

Ease of assembly wasn’t really the point here: the point was that by making the “mast” of the hydrofoil out of PCB– that’s the part that holds the underwater wing– [rctestflight] figured he could (shock!) print a circuit onto it. Specifically, a liquid-level sensor, and because microcontrollers are so cheap these days he went the “total overkill” route of embedding an ESP32 on each mast. He started with a resistive sensor, but since those self-corrode too quickly, the team switched to a capacitive sensor that doesn’t need to form a galvanic cell in salt water. Come to think of it, that might still be a problem with the solder joint between the PCBs. Good thing nobody will be riding this one.

Having such a sensor and brain close-coupled allows for a faster control loop than the sonar [rctestflight] had previously been using to control his hydrofoil’s altitude.. Pivoting each mast with its own servo made for a smooth flight over the water— well, once they got the PID tuning set, anyway. Check it out in the video embedded below.

We’ve seen PCB used for enclosures before, and even the chassis of a rover, but using it for a hydrofoil is a new hack. Continue reading “A PCB Can Be A Hydrofoil, If It Really Wants To” →

Schematic of a voltage divider

Making Actually Useful Schematics In KiCad

November 21, 2025 by 26 Comments

[Andrew Greenberg] has some specific ideas for how open-source hardware hackers could do a better job with their KiCad schematics.

In his work with students at Portland State University, [Andrew] finds his students both reading and creating KiCad schematics, and often these schematics leave a little to be desired.

To help improve the situation he’s compiling a checklist of things to be cognisant of when developing schematics in KiCad, particularly if those schematics are going to be read by others, as is the hope with open-source hardware projects.

Continue reading “Making Actually Useful Schematics In KiCad” →

A circuit board in the shape of a business card is shown. The circuitry is confined to the left side of the board, and the rest is used for text.

(Neural) Networking With A Business Card

November 15, 2025 by 13 Comments

A PCB business card is a great way for electrical engineers to impress employers with their design skills, but the software they run can be just as impressive as the card itself. As a programmer with an interest in embedded machine learning, [Dave McKinnon] wanted a card that showcased his skills, so he designed one that runs voice recognition.

[Dave] specifically wanted to run a neural network on his card, but needed to make it small enough to run on a microcontroller. Voice recognition looked like a good fit for this, since audio can be represented with relatively little data, a microphone is cheap and easy to add to a circuit board, and there was already an example of someone running such a voice recognition network on an Arduino. To fit the neural network into 46 kB, it only distinguishes the words “one” through “nine,” and displays its guess on an LED seven-segment display. [Dave] first prototyped the system with an Arduino, then designed the circuit board around an RP2040.

Continue reading “(Neural) Networking With A Business Card” →