Custom Gaming Keypad Developed with PSoC and Fusion 360

There was a time when building something yourself probably meant it didn’t look very much like a commercial product. That’s not always a bad thing. We’ve seen many custom builds that are nearly works of art. We’ve also seen plenty of builds that are–ahem–let’s say were “hacker chic”.

[AlexanderBrevig] decided to take on a project using a PSoC development board he picked up. In particular, he wanted to build a custom game keypad. He prototyped a number of switches with the board and got the firmware working so that the device looks like a USB HID keyboard.

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DIY Shapeoko 3 Enclosure

Setting up a desktop CNC brings along two additional problems that need to be resolved – noise and dust. [Nick] upgraded from a Shapeoko2 to the Shapeoko3 and decided to build a fresh dust and noise proof enclosure for his CNC , and it turned out way better than he had anticipated.

When trying to build something like this, aluminium extrusions seem like the obvious choice for the structure. Instead, he opted for low-cost steel frame shelving units. The 3mm thick steel frame results in a nice rigid structure. The top and bottom were lined with 18mm thick MDF panels. For the two sides and back, he choose 60mm noise dampening polyurethane foam lined with 6mm MDF on both sides, and held together with spray adhesive and tight friction fit in the frame.

The frame was a tad shallower and caused the spindle of the Shapeoko3 to stick out the front. To take care of this, he installed an additional aluminium frame to increase the depth of the enclosure. This also gave him a nice front surface on which to mount the 10mm thick polycarbonate doors. The doors have magnetic latches to hold them close, and an intentional gap at the top allows air to enter inside the enclosure. A 3D printed outlet port was fixed to the side wall, where he can attach the vacuum hose for dust collection. The final step was to add a pair of industrial door handles and a bank of blue LED strip lights inside the enclosure for illumination.

It’s a simple build, but well executed and something that is essential to keep the shop clean and dampen noise.

Steampunk iMacs With Real Turning Gears

Macs have always been favorites of case modders, with projects ranging from turning a Mac Plus into an aquarium to retrofuturistic machines that look like they came from the set of [Terry Gilliam]’s Brazil. Some of these casemods are of the steampunk variety, an aesthetic that usually means gluing gears to wood. [Valeriy] and [Cyrill] are bucking that trend with a beautiful iMac crafted from wood, brass, and leather (Russian, Google Translate)

The machine in question is a late-model, impossibly thin iMac. Unlike the old all-in-one computers with clunky CRTs, there’s not much space to dig around inside this iMac, and doing so would probably ruin the machine, anyway. Instead of a complete disassembly a wooden frame was constructed around the display, the aluminum base was covered in veneer, and the back of the iMac was covered in leather.

This is a steampunk computer, though, and that means gears. In this case, the gears and steam elements actually do something. The front of the computer is adorned with a decent replica of the drivetrain of a locomotive that spins with the help of an electric motor. There’s a USB port attached to the front, ensconced in a cylindrical enclosure that opens when a switch is flipped.

If a complete reworking of a modern iMac isn’t enough, the build also included the steampunkification of the Apple Bluetooth keyboard. That in itself is an amazing build, but to see the entire thing in action, you’ll have to check out the video below.

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Just In Time For The Holidays – Laser Cut Gift Boxes

If you’re anything like us, there’s a good chance that you plan on making (rather than buying) a few of your Christmas presents this year. But if past history is any indication of future success, we’ll most like run out of time and succumb to the quick-fix that only a big-box store can provide. But at least the packaging can be home made with this cool set of templates to get you started on your way.

The [Rabbitlaserusa] link has many more gift box templates than just the one shown here. In fact, we like this idea so much, we almost wonder if some of the examples could be turned into project enclosures if the right material was used – but we’re getting ahead of ourselves. We recognize that not everyone has an easy, affordable way to access a laser cutter, so just remember that these designs could be printed out and then cut by hand as well.

And, if your looking for some last minute gift ideas for kids, check out [Rabbitlaserusa] 3D animal gig saw puzzles here.

 

Hackaday Links: November 22, 2015

There’s a new documentary series on Al Jazeera called Rebel Geeks that looks at the people who make the stuff everyone uses. The latest 25-minute part of the series is with [Massimo], chief of the arduino.cc camp. Upcoming episodes include Twitter co-creator [Evan Henshaw-Plath] and people in the Madrid government who are trying to build a direct democracy for the city on the Internet.

Despite being a WiFi device, the ESP8266 is surprisingly great at being an Internet of Thing. The only problem is the range. No worries; you can use the ESP as a WiFi repeater that will get you about 0.5km further for each additional repeater node. Power is of course required, but you can stuff everything inside a cell phone charger.

I’ve said it before and I’ll say it again: the most common use for the Raspberry Pi is a vintage console emulator. Now there’s a Kickstarter for a dedicated tabletop Raspi emulation case that actually looks good.

Pogo pins are the go-to solution for putting firmware on hundreds of boards. These tiny spring-loaded pins give you a programming rig that’s easy to attach and detach without any soldering whatsoever. [Tom] needed to program a few dozen boards in a short amount of time, didn’t have any pogo pins, and didn’t want to solder a header to each board. The solution? Pull the pins out of a female header. It works in a pinch, but you probably want a better solution for a more permanent setup.

Half of building a PCB is getting parts and pinouts right. [Josef] is working on a tool to at least semi-automate the importing of pinout tables from datasheets into KiCad. This is a very, very hard problem, and if it’s half right half the time, that’s a tremendous accomplishment.

Last summer, [Voja] wrote something for the blog on building enclosures from FR4. Over on Hackaday.io he’s working on a project, and it’s time for that project to get an enclosure. The results are amazing and leave us wondering why we don’t see this technique more often.

How to Build Beautiful Enclosures from FR4 — aka PCBs

Most hobbyists say that it is easier to build a functional prototype of an electronic device, than to make the enclosure for it. You could say that there are a lot of ready-made enclosures on the market, but they are never exactly what you need. You could also use a 3D printer to build a custom enclosure, but high-end 3D printers are too expensive, and the cheaper ones produce housings which are often not robust enough, and also require a lot of additional treatment.

Another way is to build the enclosure out of FR4, a material which is commonly used in PCB production. Such enclosures are low-cost, with thin walls but yet very strong, nice looking, pleasant to the touch and have excellent thermal and moisture stability. FR4 offers some more possibilities – efficient wiring with no wires inside the housing, integrated UHF or SHF antennas or RFID coils, capacitive switches, electrical shielding, selective semi-transparency, water or air tightness, and even integration of complex mechanical assemblies.

Here I shall explain the process of building those “magic” enclosures. It is based on nearly fifty years of personal experience and more than a hundred enclosures, built for most of my projects. Here are two examples – this case for a hardware password manager is just a few centimeters long, while the other one (protective transportation cover for my son’s synthesizer) measures 125cm (about 49 inches), and yet both of them are strong enough to withstand a grown man standing on top of them.

The global approach is simple – you take the sheet of single-sided copper clad FR4, cut it and solder the parts together. That sounds simple, but there are a lot of details which should be met if you want to get top results. Please read about them carefully. You might be tempted to skip some of the steps described here, but if you do so, you will most likely end up being disappointed with the results.

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Behold! The Most Insane Crowdfunding Campaign Ever

Hold on to your hats, because this is a good one. It’s a tale of disregarding the laws of physics, cancelled crowdfunding campaigns, and a menagerie of blogs who take press releases at face value.

Meet Silent Power (Google translation). It’s a remarkably small and fairly powerful miniature gaming computer being put together by a team in Germany. The specs are pretty good for a completely custom computer: an i7 4785T, GTX 760, 8GB of RAM and a 500GB SSD. Not a terrible machine for something that will eventually sell for about $930 USD, but what really puts this project in the limelight is the innovative cooling system and small size. The entire machine is only 16x10x7 cm, accented with a very interesting “copper foam” heat sink on top. Sounds pretty cool, huh? It does, until you start to think about the implementation a bit. Then it’s a descent into madness and a dark pit of despair.

There are a lot of things that are completely wrong with this project, and in true Hackaday fashion, we’re going to tear this one apart, figuring out why this project will never exist.

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