Fully 3D Printed And Metalized Horn Antennas Are Shiny And Chrome

We’ve seen our share of 3D printed antennas before, but none as well documented and professionally tested as [Glenn]’s 3D printed and metalized horn antennas. It certainly helps that [Glenn] is the principal engineer at an antenna testing company, with access to an RF anechoic chamber and other test equipment.

Horn antennas are a fairly simple affair, structurally speaking, with a straight-sided horn-shaped “cone” and a receptacle for standardized waveguide or with an appropriate feed, coaxial adapters. They are moderately directional and can cover a wide range of frequencies. These horns are often used in radar guns and as feedhorns for parabolic dishes or other types of larger antenna. They are also used to discover the cosmic microwave background radiation of our universe and win Nobel Prizes.

[Glenn]’s antennas were modeled in Sketchup Make, and those files plus standard STL files are available for download. To create your own horn, print the appropriate file on a normal consumer-grade fused deposition printer. For antennas that perform well in WiFi frequency ranges you may need to use a large-format printer, as the prints can be “the size of a salad bowl”. Higher frequency horns can easily fit on most print beds.

After printing, [Glenn] settled on a process of solvent smoothing the prints, then metalizing them with commonly available conductive spray paints. The smoothing was found to be necessary to achieve the expected performance. Two different paints were tested, with a silver-based coating being the clear winner.

The full write-up has graphs of test results and more details on the process that led to these cheap, printed antenna that rival the performance of more expensive commercial products.

If you’re interested in other types of 3D printed antenna, we’ve previously covered a helical satcom feed, a large discone antenna, and an aluminum-taped smaller discone antenna.

Tiny Plotter Is Made Of Strings And Cardboard

If you’ve been hanging around Hackaday for any length of time, you’ve undoubtedly seen the work of [Niklas Roy]. A prolific maker of…everything, we’ve covered his projects for over a decade now. He’s one of an elite group of hackers who can say they’ve been around since Hackaday was still using black & white pictures. Yet sometimes projects fall through the cracks.

Thanks to a tip sent in from one of our beloved readers, we’re just now seeing this incredible cardboard plotter [Niklas] made for a workshop he ran at the University of Art and Design Offenbach several years ago. The fully manual machine is controlled with two rotary dials and a switch, and it even comes with a book that allows you to “program” it by dialing in specific sequences of numbers.

Not that it detracts from the project, but its worth mentioning that the “cardboard” [Niklas] used is what is known as Finnboard, a thin construction material made of wood pulp that looks similar to balsa sheets. The material is easy to work with and much stronger than what we’d traditionally think of as cardboard. Beyond the Finnboard, the plotter uses welding rods as axles and slide rails, with glue, tape, and string holding it all together.

The dials on the control panel correspond to the X and Y axes: turning the X axis dial moves the bed forward and backward, and the Y dial moves the pen left and right. The switch above the dial lowers and raises the pen so it comes into contact with the paper below. With coordination between these three inputs, the operator can either draw “freehand” or follow the sequences listed in the “Code Book” to recreate stored drawings and messages.

Believe it or not, this isn’t the first time we’ve seen somebody made a plotter out of cardboard. Though previous entries into this specific niche did use servos to move around.

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SENSEation Shows The Importance Of Good Physical Design

Sensor network projects often focus primarily on electronic design elements, such as architecture and wireless transmission methods for sensors and gateways. Equally important, however, are physical and practical design elements such as installation, usability, and maintainability. The SENSEation project by [Mario Frei] is a sensor network intended for use indoors in a variety of buildings, and it showcases the deep importance of physical design elements in order to create hardware that is easy to install, easy to maintain, and effective. The project logs have an excellent overview of past versions and an analysis of what worked well, and where they fell short.

One example is the power supply for the sensor nodes. Past designs used wall adapters to provide constant and reliable power, but there are practical considerations around doing so. Not only do power adapters mean each sensor requires some amount of cable management, but one never really knows what one will find when installing a node somewhere in a building; a power outlet may not be nearby, or it may not have any unoccupied sockets. [Mario] found that installations could take up to 45 minutes per node as a result of these issues. The solution was to move to battery power for the sensor nodes. With careful power management, a node can operate for almost a year before needing a recharge, and removing any cable management or power adapter meant that installation time dropped to an average of only seven minutes.

That’s just one example of the practical issues discovered in the deployment of a sensor network in a real-world situation, and the positive impact of some thoughtful design changes in response. The GitHub repository for SENSEation has all the details needed to reproduce the modular design, so check it out.

How Precise Is That Part? Know Your GD&T

How does a design go from the computer screen to something you hold in your hand? Not being able to fully answer this question is a huge risk in manufacturing because . One of the important tools engineers use to ensure success is Geometric Dimensioning and Tolerancing (GD&T).

A good technical drawing is essential for communicating your mechanical part designs to a manufacturer. Drafting, as a professional discipline, is all about creating technical drawings that are as unambiguous as possible, and that means defining features explicitly. The most basic implementation of that concept is dimensioning, where you state the distance or angle between features. A proper technical drawing will also include tolerances for those dimensions, and I recently explained how to avoid the pitfall of stacking those tolerances.

Dimensions and tolerances alone, however, don’t tell the complete story. On their own, they don’t specify how closely the geometric form of the manufactured part needs to adhere to your perfect, nominal representation. That’s what we’re going to dig into today with GD&T.

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Supercon: How Many Hardware Talks Can Be Packed Into One Conference?

How can we fit so many impressive talks onto two stages at the Hackaday Superconference? We’ll be bursting at the seams in November as the hardware world gathers in Pasadena for this annual pilgrimage. This year’s Supercon will have more talks and workshops than ever before!

This is the Ultimate Hardware Conference and you need to be there! We’ll continue to announce speakers and workshops as final confirmations come in. Supercon will sell out so grab your ticket now before it’s too late.

Ken Shirriff
Studying Silicon: Reverse Engineering Integrated Circuits

From the outside, integrated circuits are mysterious black boxes. Here’s how to open up some famous analog and digital chips including 8008 microprocessor, 555 timer, the first FPGA chip, Intel’s first RAM, the 76477 sound effects chip, and a counterfeit RAM chip.

Jennifer Wang
Building IMU-based Gesture Recognition

If you combine IMUs with machine learning (ML), you can detect gestures! Experimenting with these devices that sense both motion and orientation is a great way to get ML into your hacker toolkit.

Michael Schuldt
Adventures in Manufacturing Automation

A software engineer explores manufacturing automation, featuring complex software solutions and redemption in the form of reusable hardware components.

Adam McCombs
A Hacker’s Guide to Electron Microscopy

Working on electron microscopes means learning about everything from analog and digital circuit repairs, to how to rig and transport scopes, servicing 120KV+ high voltage tanks, and working on complex high vacuum systems.

Justin McAllister
Simple Antennas to Survive the Zombie Apocalypse

From $10 USB software defined radios to cheap imported transceivers, it’s easier than ever to have a multi-purpose radio in your lab. Low cost antennas can be built by beginners easily to send and receive radio signals from frequencies covering worldwide HF to local VHF, UHF, and microwave.

Alex Glow
What Went Wrong with Archimedes (the Robot Owl)?

Building a wearable, AI-powered robotic owl, is both easier and harder than it looks. Explore the challenges of 3D printing, coding, and how to confront them with creativity.

Kerry Scharfglass
The Economics of Conference Badges at Medium Scale

Discover manufacturing processes and make decisions with an eye towards economics. Buying 30,000 RGB LEDs, using big red arrows to communicate through a translator, and more!

 

Jeremy Hong
Electronic Warfare: A Brief Overview of Weaponized RF Designs

Whether you are trying to avoid having a multi-million dollar fighter jet from being shot down or avoid a speeding ticket from law enforcement , the same radar and electronic warfare equations and concepts apply.

We Want You at Supercon!

The Hackaday Superconference is a can’t-miss event for hardware hackers everywhere. Join in on three amazing days of talks and workshops focusing on hardware creation. This is your community of hardware hackers who congregate to hack on the official hardware badge and on a slew of other projects that show up for the fun. Get your ticket right away!

Malicious Component Found On Server Motherboards Supplied To Numerous Companies

This morning Bloomberg is reporting a bombshell for hardware security. Companies like Amazon and Apple have found a malicious chip on their server motherboards. These are not counterfeit chips. They are not part of the motherboard design. These were added by the factory at the time of manufacture. The chip was placed among other signal conditioning components and is incredibly hard to spot as the nature of these motherboards includes hundreds of minuscule components.

Though Amazon and Apple have denied it, according to Bloomberg, a private security contractor in Canada found the hidden chip on server motherboards. Elemental Technologies, acquired by Amazon in 2015 for its video and graphics processing hardware, subcontracted Supermicro (Super Micro Computer, Inc.) to manufacture their server motherboards in China. It is unknown how many of the company’s products have this type of malicious hardware in them, equipment from Elemental Technologies has been supplied to the likes of government contractors as well as major banks and even reportedly used in the CIA’s drone operations.

How the Hack Works

The attacks work with the small chip being implanted onto the motherboard disguised as signal couplers. It is unclear how the chip gains access to the peripherals such as memory (as reported by Bloomberg) but it is possible it has something to do with accessing the bus. The chip controls some data lines on the motherboard that likely provide an attack vector for the baseboard management controller (BMC).

Hackaday spoke with Joe FitzPatrick (a well known hardware security guru who was quoted in the Bloomberg article). He finds this reported attack as a very believable approach to compromising servers. His take on the BMC is that it’s usually an ARM processor running an ancient version of Linux that has control over the major parts of the server. Any known vulnerability in the BMC would be an attack surface for the custom chip.

Data centers house thousands of individual servers that see no physical interaction from humans once installed. The BMC lets administrators control the servers remotely to reboot malfunctioning equipment among other administrative tasks. If this malicious chip can take control of the BMC, then it can provide remote access to whomever installed the chip. Reported investigations have revealed the hack in action with brief check-in communications from these chips though it’s difficult to say if they had already served their purpose or were being saved for a future date.

What Now?

Adding hardware to a design is fundamentally different than software-based hacking: it leaves physical evidence behind. Bloomberg reports on US government efforts to investigate the supply chain attached to these parts. It is worth noting though that the article doesn’t include any named sources while pointing the finger at China’s People’s Liberation Army.

The solution is not a simple one if servers with this malicious chip were already out in the field. Even if you know a motherboard has the additional component, finding it is not easy. Bloomberg also has unconfirmed reports that the next-generation of this attack places the malicious component between layers of the circuit board. If true, an x-ray would be required to spot the additional part.

A true solution for high-security applications will require specialized means of making sure that the resulting product is not altered in any way. This hack takes things to a whole new level and calls into question how we validate hardware that runs our networks.

Update: We changed the penultimate paragraph to include the word if: “…simple one if servers with…” as it has not been independently verified that servers were actually out in the field and companies have denied Bloomberg’s reporting that they were.

[Note: Image is a generic photo and not the actual hardware]

Linux Fu: Keep An Eye On That File

One of the things that’s nice about Linux or Unix compared to many other operating systems is there’s a good chance a Linux program will spew out informational messages to a log somewhere. Many commands even have a way to turn on more logs. I know that Windows has the event viewer, but many programs don’t have much to say which makes it difficult to know what’s happening when things go wrong.

The problem is, sometimes programs tell you too much information. How do you find what you want to know? It looks cool on a movie where the hacker is in front of a terminal scrolling 500 lines a second of some log file, but in real life, it is hard to read a moving screen, although with some practice you can sometimes — unreliably — pick out a keyword as it whizzes by.

Like most Unix things, there’s a tool for that. In fact, unsurprisingly, there are many tools for that. If you are using the tail command, that’s certainly one of them. But there are others you should consider.

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