Tungsten carbide can now be found in the inventory of some jewelers, most notably as the primary material in men's wedding bands. When used in this application the bands appear with a lustrous dark hue often buffed to a mirror finish. The finish is highly resistant to scratches and scuffs, holding its mirror-like shine for years. A danger associated with this use is the occasional need to remove rings in the course of emergency medical treatment. Emergency rooms are usually equipped with jewelers' saws that can easily cut through gold and silver rings without injuring the patient when the ring cannot be slipped off easily. However, these saws are incapable of cutting through tungsten carbide.[2]

This moves the tool 80 mm (PCB size, always check this new position). And redefines the zero position for the final part.

This hole was defined in the Cherry library as a 63 mill (1,6 mm) radius and a 31.5 mill (0,8 mm) width. 1.6 + 1.6 + 0.8 should give 4 mm. But the PCB2GcodeGUI GCode file made this a 2.8 mm hole.

An online simulation shows the toolpath for this PCB. And most time is used for milling to remove copper. It would save a lot of time when the copper parts in the design are enlarged. Or by adding a ground (GND) which is conneced to large copper planes on the board. This file made with Fusion 360 isn't perfect. But, with some changes, it can be used to create a PCB.

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In this Instructable I combine these two items: Controlling a dremel with an Anet A8 printer. This won't be a fast and very strong CNC machine, but it should be capable of making PCBs.

This is the GCode for a single sided PCB. It is posible to create a double sided PCB, but this requires 2 GCode files: One for each side. I would start with the top side, and drill two holes at two (or four) corners of the PCB (0,0 and 80,80) just before etching the topside. These additional holes can be used to align the board for the bottom side. And draw horizontal lines on the print bed to facilitate repositioning.

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The first PCB failed for two reasons. First, the mill wasn't close enough onto the PCB in two corners: The mill must be placed just above the copper layer. You can use a multimeter to measure the height. Move the toolhead down very slowly. And stop if the resistance between the tool and the PCB equals 0 Ohm.Or turn on the dremel and move the toolhead down very slowly. And stop as soon as the mill removes some material.

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I have some experience with hand routers, and I've made a drone frame with a dremel router once. Unfortunately this router isn't accurate enough to make PCBs.

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Secondly, the first move command didn't work as expected: Normally the Anet A8 homes to (0,0,0) by usage of the end switches. Then it moves to it's initial position above the heatbed and sets this position to (0,0,0). This initial homing is also executed when I start my custom GCode file. It moved the entire PCB 30 mm on the x-axis and 10 mm on the y-axis.

The Gerber files from the Eagle software must be converted to Gcode files. I found two programs to make this conversion:

These Gerber files can't be used with the Anet A8 printer. But it's posible to use these files to create the required files. All generated files are textfiles and contain X and Y positions for all copper traces, solder masks and drills.

The 3D printer used in this Instructable is an Anet A8. This is a cheap Prusa based 3D printer (about €130, $150) with which you can make fine 3D prints. How to build and improve this printer is described in my previous Instructable: "Buid and Improve a 3D printer".

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The yellow lines are the signal wires. These must be replaced by routes. These routes can be placed on the Top (layer 1, red) or bottom (layer 16, blue). Only the blue lines will be 'etched' by the dremel. Both layers can be connected by a 'Via', but this results in a wire bridge.

Secondly, it showed some 'problems' which would not have happened with regular components. These keys have a mount point for exact positioning. This requires a hole with a diameter of 4 mm. And the dremel can't handle 4 mm tools. In addition to etching and drilling, it is therefore also necessary to mill.

It has been a few decades since I have designed and etched my last PCB. And for some future projects, I want to make small PCBs myself. These will not be complex, just one or two layers. And I would rather not use any chemicals. That is why I decided to make PCBs using a CNC machine.

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All other settings depend on the mill size and board height. The sample settings are for a 0.8 mm mill and a 1.6 mm PCB board.

At some points the diameter of the 0.8 mm mill is too large. The default resolution for the pin headers is 2.54 mm (1/10 inch). This is the distance between the holes in a prototyping PCB board. A 0.8 mm mill leaves 1.75 mm for the pad. And a hole of 0.8 mm will be drilled in the middle of this pad. Leaving 0.5 mm on the short side, and 1 mm on the long side.

This moves the dremel 5 cm above the home position. The last command moves the dremel almost to the middle of the working area. The M114 command gives the current position: X:100.00 Y:100.00 Z:50.00 E:0.00. The idea is to place the toolhead to the exact start position (with pronterface) and make this the new home position (0,0,0):

Use double sided adhesive tape to attach the PCB. It is important to level the bed with the PCB attached. I've used the same method as leveling a 3D printer. Use a sheet of paper, and level the bed at 4 points. This will be the Z=0 height.

The first program is an add-on to the Eagle software. And the other program is a stand alone program which converts Gerber files to Gcode files.

The sample schematic is very simple. It can easily be made with Fusion 360. However, all components/holes and traces must be created manually. And this is hard to manage for large/complex PCBs.

I've modified the sample schematic to prevent ghosting. The three resistors are optional, and can be used as pull up/down resistor.

Autodesk Eagle can be used to design electrical diagrams. The software is free for DIY projects, and can handle PCBs up to 80 cm2.

The back, drill and outline files are required for this PCB. Uploading these files to a GCode viewer shows the toolpaths for these GCode files.

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The 3D printer firmware uses Gcode to control the printer. When creating a 3D print, this code is created during the slicing of the STL file. This Gcode file contains all commands to control the electronic parts. It is a readable textfile with a fixed format:

The first step in the Eagle software is to create the schematic. Use the components from the modified libraries and arrange them on the screen. Use the net (green line) tool to connect the components. Don't use the draw tool for this.

All keys are placed in a matrix, and it requires some software (or library) to read the keys with an Arduino. I've made a 4 x 4 example on Tinkercad. The code isn't optimized, which makes it very readable. All input pins are defined as INPUT_PULLUP. They always return TRUE (1) unless they are connected to the GND or a LOW (output) pin. The program starts with setting pin 5 to LOW. This makes it possible to measure all values of the four buttons in row 1. And continues with the other rows.

I have made some adjustments in the Cherry library and some other default Eagle libraries.I'm using a 0.8 mm cutter to create the PCB. As a result, the mimimum distance between the copper paths is also 0.8 mm. And I don't plan to replace the tool while making the PCB: All component holes will be at least 0.8 mm.

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These files can be send to a PCB manufacturer. This board can be manufactured for about $10. With about $10 shipping costs.

Open the PCB and press the ULP button. Now select the ulps-folder instead of the examples folder and start with opening the setup file. The Anet a8 requires the "generic.pp" setup file.

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There are two types of Cherry keys: PCB and housing mounted. The PCB (direct) mounted versions have three mounting pins and are only available from Cherry itself. The general available housing version has only one mounting pin.

Carbide cutting surfaces are often useful when machining through materials such as carbon steel or stainless steel, as well as in situations where other tools would wear away, such as high-quantity production runs. Sometimes, carbide will leave a better finish on the part, and allow faster machining. Carbide tools can also withstand higher temperatures than standard high speed steel tools. The material is usually tungsten-carbide cobalt, also called "cemented carbide", a metal matrix composite where tungsten carbide particles are the aggregate and metallic cobalt serves as the matrix. The process of combining tungsten carbide with cobalt is referred to as sintering or Hot Isostatic Pressing (HIP). During this process cobalt eventually will be entering the liquid stage and WC grains (>> higher melting point) remain in the solid stage. As a result of this process cobalt is embedding/cementing the WC grains and thereby creates the metal matrix composite with its distinct material properties. The naturally ductile cobalt metal serves to offset the characteristic brittle behavior of the tungsten carbide ceramic, thus raising its toughness and durability. Such parameters of tungsten carbide can be changed significantly within the carbide manufacturers sphere of influence, primarily determined by grain size, cobalt content, dotation (e.g. alloy carbides) and carbon content.

Although the process seems complicated, it has the advantage that no chemicals are used. I am therefore satisfied with the end result, and will create a PCB with this method more often in the future.

Tungsten is a very hard and dense metal, mined from Wolframite ore and symbolized by a (W) on the periodic table of elements. It melts at an extraordinary 6,192 °F (3422 °C) – the highest melting point of all metals. On its own, tungsten is vulnerable to scratches and damage just like any other metal, such as titanium and steel. Tungsten does not gain its extreme hardness until it is combined with a carbon alloy, transforming it into tungsten carbide (WC) with a hardness between 8.5 and 9.5 on the Mohs hardness scale. Tungsten carbide is four times harder than titanium, twice as hard as steel, is virtually unscratchable, and has been widely used for decades in industrial applications such as cutting tools, mining machinery, and rocket engine nozzles. Its extreme hardness makes it useful in the manufacture of cutting tools, abrasives and bearings, as a cheaper and more heat-resistant alternative to diamond. Tungsten carbide is also used as a scratch-resistant material for jewelry including watch bands and wedding rings.

Hard carbides, especially tungsten carbide, are used by athletes, generally on poles which impact hard surfaces. Trekking poles, used by many hikers for balance and to reduce pressure on leg joints, generally use carbide tips in order to gain traction when placed on hard surfaces (like rock); such carbide tips last much longer than other types of tips. Rocks along many popular hiking trails, such as the Appalachian Trail and Pacific Crest Trail, are scratched and pockmarked from hundreds or thousands of impacts from pole tips.[citation needed]

First, the keys must have exactly the same distances apart. With a handmade PCB (etching and drilling) these holes will never be exactly in the right place. And with a keyboard you want the keys to be exactly aligned. Otherwise, it looks messy.

It takes a 3D printer firmware modification before this 50% GCode files can be used. The stepsize of the stepper drivers must be adjusted by 2 (for X and Y). This will translate the 80 x 80 cm board (at 50%) to a 160 x 160 cm board.

Tungsten carbide ammunition can be of the sabot type (a large arrow surrounded by a discarding push cylinder) or a subcaliber ammunition, where copper or other relatively soft material is used to encase the hard penetrating core, the two parts being separated only on impact. The latter is more common in small-caliber arms, while sabots are usually reserved for artillery use.

The second part which went wrong are the 9 holes for the keys. They were only 2.8 mm instead of 4 mm. This was caused by a setting in PCB2Gcode.

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The PCB design must be saved in a readable format before it can be processed further. This is done with the CAM-processor. I've used the default values, and processing creates two folders in the project folder:

This is the next step to create the PCB. Pressing the "Manufacturing" button opens a preview window. This window shows both sides and all drills (top side only).

In the second attempt, I 'printed' the individual files separately. Using the workflow of the previous step. This gave an usable PCB:

I've choosen to use a 0,8 mm mill. This makes it possible to make this simple PCB. The GCode viewer and Machine code simulator has been used to show the toolpath for the etch-operations before. And it shows all milling operations for the PCB.

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The standard Eagle libraries contains components with a thinner hole diameter. With the corresponding pads. However, these pads are too small for the 0.8 mm cutter/drill. So I adjusted the pads of all components used on this PCB. I gave them a diameter of 3 mm, with a hole of 0.8 mm.

The Outline "Edge line width" setting in PCB2GcodeGUI influences the size of these holes. It creates a 3.2 + 0.8 mm hole when set at 0.8. And I've used the value of 0.4 mm for this PCB.

There are two Instructables which explain how to "get started with CNC" with fusion 360. And I've managed to create a PCB and convert it to a GCode file. This is a file which contains all instruction for the 3D printer:

It's even posible to alter the mill between the GCode files. The printer remembers the home position, even after moving the toolhead by the menu.

This GCode, made with Fusion 360, can be modified to be used with my Anet A8 3D printer. The first eight lines (header) must be modified. But the lines starting with G0 and G1 contain all required movements for the 3D printer.

I also have experience with 3D printers. My previous Instructable was about creating and improving an Anet A8 3D printer.

Remove the heatbed and replace it with a piece of MDF with the same size. The PCB will be attached to this plate with double-sided adhesive tape. The advantage of MDF is that it is flat. You can place the MDF on top of your heatbed, but make sure you don't drill into your heatbed!

I haven't used the Fusion 360 output to create a PCB. But this example shows the workflow of making a PCB with a CNC machine:

The X and Y movements are from 39.96363 to 41.96352 (X) and from 41.85072 to 39.85082 (Y). A distance of 1.999 mm. And 0.8 mm for the tools gives a total size of 2.8 mm.

PCB-GCode is an "user language program" for the Eagle software. It contains two programs: pcb-gcode and pcb-gcode-setup. Download the "pcb-gcode-3.6.0.4.zip" file and extact all files in the ulps folder of the Eagle directory.

I'm using Pronterface for a while to test 3D printers. It's easy to install and use, but it's getting old. The latest version is from november 2017. Download the file and extract all files to a folder (no need for installation). There is a command line and graphical version. Start pronterface.exe for the graphical version. Connect the printer with an USB cable. Select the com port (eg com4) and a bautrate of 115200 and press the connect button. There are 4 home buttons: Start with the Y axis, then the X axis and finally the Z axis.

Remove the extruder, the fan and the metal extruder carriage. And attach the dremel to the 3 linear guides for the X axis.

The Cherry keys require a 0,059 inch (1.5 mm) hole for the pins. And I've used a 0.0320 inch (0.8 mm) tool. This can be solved by adding these holes to the milling GCode file. Or by changing the tool while drilling the PCB. I only ordered some 0.8 mm mills, and have to order different sizes for my next PCB.

This allows the toolhead to move to any position! The hardware endstops are still enabled, but there are only 3 of them.

The feedrade for these small mills should be about 1% of the diameter per revolution. These bits might break when moving at higher speeds. And milling at slower speed will wear the bit faster.

All X, Y and Z coordinates in the gcode file are absolute. The Home position equals (0,0,0) and the middle of the heatbed equals (110,110,0).

Monotungsten carbide, WC, or Ditungsten Carbide, W2C, is a chemical compound containing tungsten and carbon, similar to titanium carbide.

All keys are placed on a 20 x 20 mm raster. Use the properties (i) tool to position all objects (s1 = 20,60 ; s2 = 40,60 ; s3 = 60,60 ; s4 = 20,40 ; s5 = 40,40 ; s6 = 60,40 ; s7 = 20,20 ; s8 = 40,20 ; s9 = 60,20 ). The milimeters are automaticly converted to mill (one thousandth of an inch). Choose a logical location for the diodes, resisors and pins.

The generated GCode files contains negative X values. Both axis (X, Y) of the bottom etch/drill files start in the lower right corner. This is shown in the viewer image (crosshair on second image).

Many manufacturers of this emerging jewelry state that the use of a cobalt binder may cause unwanted reactions between the cobalt and the natural oils on human skin. Skin oils cause the cobalt to leach from the material. This is said to cause possible irritation of the skin and permanent staining of the jewelry itself. Many manufacturers now advertise that their jewelry is "cobalt free". This is obtained by substituting the cobalt with nickel as a binder.[citation needed]

Zooming with the GCode viewer shows small differences between both etch files.The Eagle GCode makes larger pads and thicker copper traces. But it doesn't mill the 9 holes for the keys, and cuts the outline in a single pass.

Tungsten carbide is also an effective neutron reflector and as such was used during early investigations into nuclear chain reactions, particularly for weapons. A criticality accident occurred at Los Alamos National Laboratory on 21 August 1945 when Harry K. Daghlian, Jr. accidentally dropped a tungsten carbide brick onto a plutonium sphere causing the sub-critical mass to go critical with the reflected neutrons.

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Tungsten carbide is often used in armor-piercing ammunition, especially where depleted uranium is not available or not politically acceptable. The first use of W2C projectiles occurred in Luftwaffe tank-hunter squadrons, which used 37 mm autocannon equipped Ju-87G Stuka attack planes to destroy Soviet T-34 tanks in WWII. Owing to the limited German reserves of tungsten, W2C material was reserved for making machine tools and small numbers of projectiles for the most elite combat pilots, like Hans Rudel. It is an effective penetrator due to its high hardness value combined with a very high density.

This instructable replaces step 3. I'll be my own manufacturer, making the PBC. This reduces cost, and I don't have to wait a few days for my PCB to arive.

This instructable uses the Autodesk Eagle PCB design tool. I started with the Circuit Board Design Class. In this course an electrical diagram is made in Autodesk Eagle (lesson 2). This is converted into a PCB design (lesson 3). And from this point the course continues with selecting a manufacturer for the PCB.

The dremel 4000 has a speed between 5000 and 35000 rpm. Running at half speed with flexible shaft gives about 17.000 rpm.

Installing the Eagle software is easy. Installing the library and the gcode plugin is also easy. To do this, certain files must be placed in certain folders after installation of the Eagle software: Place all libraries in the "libraries" folder and extract the pcb-gcode-archive in the "ulps" folder.

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After some research and experimenting, I managed to make a PCB with an Anet A8 3D printer. And after some practice it should be possible to make double-sided PCBs. With these it is especially important to calibrate the starting position properly.

The free version of eagle allows for boards up to 80cm2 (about 9 x 9 cm). Larger PCBs require a subscription. It is posible design two PCBs in Eagle and 'etch/mill' them on a single PCB. It requires exact postioning before starting the second GCode-file, but this is a method to make a large PCB.

Open the cherry.lbr file in Eagle (libraries > libraries > double click on "cherry.lbr"). Double click on the CHERRY_MX footprint to open an editor to adjust the footprint.

By designing the PCB at a half scale (50%), all the advantages of Eagle are retained. A single schematic, and a single PCB design. This requires a custom library with Cherry Keys at half the original size. This can be done with usage of a few different components (one type resistor, switch and diode). And all traces must be at half the thickness.

Then remove the header from the etch-file and load it with Pronterface. Press print to execute all commands after starting the Dremel tool.

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At this point it's posible to load the Fusion 360 GCode file and execute the Gcode commands. This doesn't have to be a PCB.

This dremel holder is made for the "Dremel 225-01 Flex Shaft Attachment". This fits all dremels, and ensures that less weight is attached to the X axis. If you have another brand multi tool, you can easily design and print a holder yourself.

While ski pole tips are generally not made of carbide, since they do not need to be especially hard even to break through layers of ice, rollerski tips usually are. Roller skiing emulates cross country skiing and is used by many skiers to train during warm weather months. Because skiers require traction on bitumen (asphalt) carbide tips are used in the sport.[citation needed]

The PCB2GcodeGUI files contain GCode which isn't compatible with the Anet A8 printer. The orginal output contains some invalid commands:

The Eagle Cherry library only contains the PCB version with 3 holes. You can modify the library file with a text editor, or by altering the library in Eagle itself.

This file contains several layers, and the holes are placed on layer 44 (drills). I've removed all three mount points, and added a milling operation for the 4 mm hole in the center. The two pads are enlarged and modified for the drilling bit.

The Anet A8 printbed limits the PCB size to to 22 x 22 cm (484 cm2). About 6 times the maximum PCB size of 80 cm2. This is too small for a regular keyboard. But sufficient for an Ergodox style keyboard. It requires about 4 different PCB designs combined into a single GCode file.

Some tire manufacturers, such as Nokian and Schwalbe, offer bicycle tires with tungsten carbide studs for better traction on ice. These are generally preferred over steel studs because of their wear resistance.

The sample GCode files use a speed of 100 mm/min. And 100/17,000 = 0.0058 mm. This is the removed material at a single rotation.The rule of thumb equals 1% of 0,8 mm = 0,008 mm. The current speed should be fine.

This command makes the current positon (100,100, 50) the new home position (0,0,0). And the following command move the toolhead to a location, and back to this initial (new home) position:

I usually make the design of an electrical diagram on paper. And after some iterations this results in a workable schedule for a prototype PCB.

Tungsten carbide rings can actually be removed in an emergency situation by cracking them into pieces with standard vice grip–style locking pliers. Although standard ring cutting tools cannot be used due to the hardness of this material, there are specialty cutters available that are just as effective on tungsten carbide as they are on gold and platinum.

It is posible to press multiple buttons at the same time. And the program returns a value for each button. But there is one problem with some combinations. Pressing three buttons might result in detecting 4 buttons. This is called ghosting and can be solved by adding a diode for each button.

At this point I've managed to make a PCB with my 3D printer. The next step is to clean the board and solder some Cherry keys and diodes.

The sample project in this Instructable is a PCB board for a Cherry keys tester. These 9 keys will be connected just like a 4 x 4 keyboard module.

Machining with carbide can be difficult, as carbide is more brittle than other tool materials, making it susceptible to chipping and breaking. To offset this, many manufacturers sell carbide inserts and matching insert holders. With this setup, the small carbide insert is held in place by a larger tool made of a less brittle material (usually steel). This gives the benefit of using carbide without the high cost of making the entire tool out of carbide. Most modern face mills use carbide inserts, as well as some lathe tools and endmills.

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Disconnect the headbed, thermistors, fans and extruder from the heatbed. Leave the end-stops and X,Y and Z-motors connected and place the Z endstop at the maximum height. Keep the LCD screen connected, to load GCode files from the SD card.

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The two methods in the previous steps give different outputs. Both methods can't be combined directly for a single PCB. The Eagle Gcode files uses negative values for the X coordinates and the PCB2GcodeGUI uses positive values for the X coordinates. The image shows the result of both operations without any modifications.

I've also modified the diode (1N4148), resistor (0204/7) and pinheader (3 and 4 pins) libraries. All pads are enlarged to 3 mm with a 0.8 mm hole. Copy all files from the zipfile to the libraries folder in the Eagle documents directory. All four libraries must be enabled (Library > Open Library manager > Available Tab > Cherry > Use), which is indicated by a green dot.

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I've made a number of projects and Instructables with electronic circuits. And most of them used a prototyping PCB. This works fine, and it's a quick way to finish a project. But creating a PCB yourself gives a project a more professional appearance. It looks less messy, and reduces the chance of faults and defects. That is why I started researching how to make PCBs.

To increase the life of carbide tools, they are sometimes coated. Four such coatings are TiN (titanium nitride), TiC (titanium carbide), Ti(C)N (titanium carbide-nitride), and TiAlN (Titanium Aluminum Nitride). (Newer coatings, known as DLC (Diamond Like Coating) are beginning to surface, enabling the cutting power of diamond without the unwanted chemical reaction between real diamond and iron.) Most coatings generally increase a tool's hardness and/or lubricity. A coating allows the cutting edge of a tool to cleanly pass through the material without having the material gall (stick) to it. The coating also helps to decrease the temperature associated with the cutting process and increase the life of the tool. The coating is usually deposited via thermal CVD and, for certain applications, with the mechanical PVD method. However if the deposition is performed at too high temperature, an eta phase of a Co6W6C tertiary carbide forms at the interface between the carbide and the cobalt phase, facilitating adhesion failure of the coating.

Move the milling tool to the start position with the milling tool just above the PCB (one sheet of paper, Z=0). This will be the new home position. The Eagle GCode file starts at the right lower corner, and the PCB2GcodeGUI file starts at the left lower corner.