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Digital Caliper: Capacitive Scale and Slider with Two-Chip Electronics (Baxter and Buehler, Starrett, 1986)
Ed

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Ed

2. November 2026FI
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Digital Caliper: Capacitive Scale and Slider with Two-Chip Electronics (Baxter and Buehler, Starrett, 1986)

A six-inch caliper that reads out on a display. Under the slide, a strip of etched copper bars runs along the beam. Electrodes on the slider pass a signal through the bars by capacitance, and the slider's electronics count the bars crossed and work out the position in between. Result: a digital caliper reading in inches or millimetres, repeatable to a ten-thousandth of an inch, with floating zero, peak hold and high/low limits. It runs on two 1.5 V cells at 10-50 microamps. Source: L. K. Baxter and R. J. Buehler (L. S. Starrett Co.), US Patent 4,586,260 (1986). Unknown: the metal of the beam, slide and rod, their dimensions, the processor's program, and how the chips and display are made. Ours: the etchant, photoresist and glue. Picture: Wikimedia Commons.
Advanced
2 days

Instructions

1

Etch the scale

Etch the scale pattern onto a strip of copper-clad epoxy fibreglass with photoresist and etchant. Each copper bar is 0.40 inch long, with a wider centre 0.12 inch long and two ends 0.14 inch long. Space the bars on 0.05 inch centres: the centres sit 0.004 inch apart, the ends 0.025 inch apart. Run the pattern the full length of the scale. Ours: dry film resist and ferric chloride.

Materials for this step:

PCB Blank (Copper Clad)PCB Blank (Copper Clad)1 strip, length of the beam

Tools needed:

Dry Film PhotoresistDry Film Photoresist
Ferric Chloride SolutionFerric Chloride Solution
Chemical-Resistant GlovesChemical-Resistant Gloves
2

Fix the scale into the beam

The beam is a metal bar with the fixed outside and inside jaws at one end, a wide shallow channel in its face and a second channel along its back. Fix the scale permanently into the face channel, copper up. The patent allows etching before or after this step. Not given: the metal, the dimensions and how the scale is fixed. Ours: epoxy.

Materials for this step:

Caliper BeamCaliper Beam1 with integral jaws
Two-Part Epoxy Adhesive (Quick Set)Two-Part Epoxy Adhesive (Quick Set)1 a little

Tools needed:

Unknown DimensionsUnknown Dimensions
3

Fit the parts to the circuit

The circuit is one folded piece: a double-sided slider board joined by a flexible hinge to a circuit board. Its bottom face has two pickup electrodes, 0.750 x 0.110 inch and 0.0625 inch apart. On each side of them is an interdigitated transmitter array: fingers 0.115 inch long on 0.025 inch spacing, opening to 0.0375 inch at the centre. On the circuit board, solder or wire-bond the two chips: an NEC uPD7503 3 V processor (768 bits RAM, 2 kB ROM) and a CMOS gate array. Then fit the LCD, the 100 kHz crystal, the integrating capacitor and the MODE and SET buttons. Not given: the processor's program. Ours: a capacitor from a kit.

Materials for this step:

Rigid-Flex Circuit BoardRigid-Flex Circuit Board1 slider board + circuit board
Integrated CircuitIntegrated Circuit2 uPD7503 CPU, CMOS gate array
Segment LCD PanelSegment LCD Panel1 5 digits
Quartz CrystalQuartz Crystal1 100 kHz
Capacitor KitCapacitor Kit1 one integrating capacitor
Push ButtonPush Button2 MODE, SET
Solder WireSolder Wire1 a little

Tools needed:

Soldering IronSoldering Iron
4

Build the slide

The slide frame wraps the back and edges of the beam and carries the movable jaws. Fix it to the depth rod, which runs in the back channel of the beam; the rod's free end is the depth gauge. Put the moulded plastic housing between the frame ends. Fasten two metal wear strips under the slider board, one on each side of the scale. They ride on the beam and connect the board's copper to it. Not given: the metal and sizes.

Materials for this step:

Caliper Slide FrameCaliper Slide Frame1 with jaws
Unknown MetalUnknown Metal1 depth rod and two wear strips
Caliper Slide HousingCaliper Slide Housing1 piece

Tools needed:

Unknown DimensionsUnknown Dimensions
Precision Screwdriver SetPrecision Screwdriver Set
5

Assemble and check

Fold the circuit into the housing recess, slider board facing the scale, and screw it to the frame. The electrodes must lie parallel to the scale bars at every point of travel. Put the two 1.5 V cells (the patent says 'zinc oxide') in the battery pockets of the circuit. The display shows five digits, a ten-thousandths bar graph, a minus sign and 'mm', plus PEAK, LOW, HIGH and LIMIT. Ours: check the reading against a vernier caliper.

Materials for this step:

Machine ScrewsMachine Screws2 pieces
1.5 V Button Cell1.5 V Button Cell2 pieces

Tools needed:

Precision Screwdriver SetPrecision Screwdriver Set
Vernier CaliperVernier Caliper

Materials

15

Tools Required

7

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