Fixing A Dodgy Cheap Audio DAC

One of the attractions of buying at the bottom end of the electronics market by mail order from China is that you never quite know what will come your way. Sometimes it’s a diamond in the rough, while with others it’s a mess. Occasionally along comes something which should work but doesn’t, and that’s the moment when you wonder if you could fix it. [Nyanpasu64] had just such a device, an HDMI to VGA converter with audio that didn’t work. What could be wrong?

The HDMI to VGA chip has an onboard audio digital-to-analog converter (DAC), and it’s a delta-sigma design. This type of DAC is frequently used in audio applications because it works by shifting its switching frequency many times higher than the input sample rate, thus reducing considerably the distortion. This one wasn’t performing as advertised though, and the problem turned out to be that switching frequency being all over the output. Clearly the filter wasn’t working, which led to the design of a new filter. The write-up is therefore an extensive dive into filter design, and in part also a discovery of the effect of impedance on them.

For a super-cheap module to cause so much work, one might ask why not simply spend a few more dollars and get a better one. But had they done that we wouldn’t have seen this write-up, so we’re sticking with team cheap.

We’ve looked at audio DACs, in the past.

Die Casting Comes Home

You don’t normally think of die casting as something to do at home. Pressurized fluids demand respect at all times, which is perhaps in part why we see most projects skipping hydraulics for linear actuators. When the pressurized fluid is molten metal? Well, we’d say don’t try this at home, except that’s exactly what this video by [Know Art] is making us want to do. He’s doing die-cast aluminum, and it looks way easier than we thought it would.

If you’re wondering why anyone would attempt such a thing, it’s for the same reason die-casting has been an industrial powerhouse for the last couple hundred years — you can crank out a lot of parts, very quickly, with excellent detail and dimensional stability. You just need a mold, which in this process is called a die, and a way to squeeze metal into it with some force.

In this case the die was carved on a desktop CNC machine. Depending on how long you want your die to last, you’ll need something hard and heat resistant, like the graphite used in this video. Graphite is also used in constructing the piston for the injector, which is made from a modified hydraulic cylinder and a couple of old trampoline springs.

He first tests the setup with molten wax before moving onto aluminum, as the process is the same regardless: pour the hot liquid in, release the springs to provide the pressure that forces it into the die, and a part is made. It looks easy, if a bit frantic, as you have to work fast before the metal cools in the cylinder.

After CNC milling, EDM machining and all the fun things we’ve learned how to do with lasers and 3D printers, and now this we’ve got to wonder– is there any industrial process you can’t hack onto your desktop? We’ve even seen the chemists get in on the game.

Continue reading “Die Casting Comes Home”