The laser module shown cutting shapes out of a piece of cardboard that's lying on the CNC's work surface

Giant CNC Partners With Powerful Laser Diode

April 30, 2022 by Arya Voronova 13 Comments

[Jeshua Lacock] from 3DTOPO owns a large-format CNC (4’x8′, or 1.2×2.4 m), that he strongly feels is lacking laser-cutting capabilities. The frame is there, and a 150 W CO2 laser tube has been sitting in a box for ages – what else could you need? Sadly, at such a scale, aligning the mirrors is a tough and finicky job – and misalignment can be literally blinding. After reading tales about cutters of such size going out of alignment when someone as much as walked nearby, he dropped the idea – and equipped the CNC head with a high-power laser diode module instead. Having done mirror adjustment on a few CO2 tube-equipped lasers, we can see where he’s coming from.

Typically, the laser modules you see bolted onto CNC heads are firmly under three watts, which is usually only enough for engraving. With a module that provides 5 watts of optical power, [Jeshua] can cut cardboard and thin plywood as well he tells us even 10 W optical power modules are available, just that he didn’t go for one. We reckon that 20 W effective power diodes are not that far into our future, which is getting very close to the potential of the blue box “40 W but actually 35 W but actually way less” K40 laser cutters we cherish. [Jeshua]’s cutter is not breaking speed limits, but it’s built on what’s already there, and the diode is comparatively inexpensive. Equipped with a small honeycomb surface and what seems to be air assist, it’s shown in the video cutting an ornamental piece out of cardboard!

We hackers have been equipping CNCs with laser diodes for a while, but on a way smaller scale and with less powerful diodes – this is definitely a step up! As a hacker, you should have at least some laser cutting options at your disposal, and this overview of CO2 cutters and their availability can get you started. We’ve also given you detailed breakdowns about different sides of laser cutting, be it the must-have of safety, or the nice-to-have of air assist.

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ITman496 in his ATV, using the trashcan lifter to lift a trashcan up in the air. The lifter is a contraption mounted to the front of his ATV, welded together with square tubing

Equipping An ATV With A Trashcan Lifter

April 29, 2022 by Arya Voronova 6 Comments

[ITman496] is one of us hackers working his way around health problems, in his case, a back injury. He is eager to solve various difficulties he has to deal with, and in case of the video he made, it was about moving a large trashcan through ice-covered roads on his property. Not willing to risk his health any further and dissatisfied with the flimsy solutions for sale requiring him to do the heavy lifting, still, he designed and built a winch-powered trashcan lifter mechanism – not entirely unlike a forklift. He mounted it to his ATV, tested it, improved upon it, filming his progress along the way – and then made a video detailing the entire build for us!

Having sketched the concept on his phone, he modeled and tested it in SketchUp, then cut and welded the parts, describing a welding alignment trick along the way – using 3D-printed joints to hold the two parts-to-be-welded together for tack welds, ensuring nigh-perfect alignment. Initial testing was a success! From there, he describes a good few surprising but in retrospect expected ease-of-use improvements that didn’t crop up during simulations, like adding chamfers to the scoop, so that he doesn’t have to angle his ATV super precisely to pick the trashcan up. In the end, having used it for about a month now, he tells us it’s been working extremely well for his purposes!

Not all such garbage cans need to be taken out, thankfully – some of them go voluntarily, and you can even get smaller ones that catch stuff you throw from across the room. We’ve covered the adventures of [ITman496] before, learning lessons from a failed robot build in 2016., and adopting an ultralight plane in 2018!

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Stanislaw playing notes on his MIDI keyboard, with the LEDs on the LED strip lighting up right above the note he's playing, driven by the Raspberry Pi that runs a script based on the Pianolizer toolkit

Pianolizer Helps Your Musical Projects Distinguish Notes

April 26, 2022 by Arya Voronova 9 Comments

[Stanislaw Pusep] has gifted us with the Pianolizer project – an easy-to-use toolkit for music exploration and visualization, an audio spectrum analyzer helping you turn sounds into piano notes. You can run his toolkit on a variety of different devices, from Raspberry Pi and PCs, to any browser-equipped device including smartphones, and use its note output however your heart desires. To show off his toolkit in action, he set it up on a Raspberry Pi, with Python code taking the note data and sending color information to the LED strip, displaying the notes in real time as he plays them on a MIDI keyboard! He also created a browser version that you can use with a microphone input or an audio file of your choosing, so you only need to open a webpage to play with this toolkit’s capabilities.

He took time to make sure you can build your projects with this toolkit’s help, providing usage instructions with command-line and Python examples, and even shared all the code used in the making of the demonstration video. Thanks to everything that he’s shared, now you can add piano note recognition to any project of yours! Pianolizer is a self-contained library implemented in JavaScript and C++ (which in turn compiles into WebAssembly), and the examples show how it can be used from Python or some other language.

[Stanislaw] also documented the principles behind the code, explaining how the note recognition does its magic in simple terms, yet giving many insights. We are used to Fast Fourier Transform (FFT) being our go-to approach for spectral analysis, aka, recognizing different frequencies in a stream of data. However, a general-purpose FFT algorithm is not as good for musical notes, since intervals between note frequencies become wider as frequency increases, and you need to do more work to distinguish the notes. In this toolkit, he used a Sliding Discrete Fourier Transform (SDFT) algorithm, and explains to us how he derived the parameters for it from musical note frequencies. In the end of the documentation, he also gives you a lot of useful references if you would like to explore this topic further!

What are you going to build with this? Maybe, a box that records you playing the flute and instantly turns it into sheet music? Or, perhaps, an AI that continues the song for you when you stop?

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Insteon Abruptly Shuts Down, Users Left Smart-Home-Less

April 25, 2022 by Arya Voronova 88 Comments

In today’s “predictable things that happened before and definitely will happen again”, Insteon, a smart home company boasting the Insteon ecosystem of devices built around their proprietary communication standards, has shut down their servers without a warning. For almost two decades, Insteon used to offer products like smart light switches, dimmers, relays, various sensors, thermostats – the usual home automation offerings, all linked into a cozy system. Looking through the Insteon subreddit’s history, there were signs of the company’s decline for good half a year now, but things were mostly stable – until about a week ago, when users woke up and noticed that parts of their smart home network stopped working, the mobile app would no longer respond, and the company’s resources and infrastructure went down. What’s more – the C-rank management has scrubbed their LinkedIn profiles from mentioning Insteon and SmartLabs (Insteon’s parent company).

Instantly, the Insteon subreddit has livened up. People, rightfully angry about being literally left in the dark, were looking for answers – as if mocking them, Insteon’s homepage claimed that all services were operational. Others, having expected the shutdown to eventually happen, started collecting and rehosting rapidly disappearing documentation, helping each other keep their tech up in the meantime, and looking into alternative platforms. It turned out to be imperative that users don’t factory reset their Insteon hubs, since those have to communicate with the currently Inste-Gone servers as part of initial configuration, diligently verifying the SSL certificates. Sadly, quite a few users, unaware and going through the usual solutions to make their network function again, are now left with hubs that are essentially bricked, save for a few lucky ones.
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The dash of Xiaomi Mi 1S scooter, with the top panel taken off and an USB-UART adapter connected to the dashboard, sniffing the firmware update process

Xiaomi Cryptographically Signs Scooter Firmware – What’s Next?

April 24, 2022 by Arya Voronova 33 Comments

[Daljeet Nandha] from [RoboCoffee] writes to us, sharing his research on cryptographic signature-based firmware authenticity checks recently added to the Xiaomi Mi scooter firmware. Those scooters use an OTA firmware update mechanism over BLE, so you can update your scooter using nothing but a smartphone app – great because you can easily get all the good new features, but suboptimal because you can easily get all the bad new features. As an owner of a Mi 1S scooter but a hacker first and foremost, [Daljeet] set up a HTTPS proxy and captured the firmware files that the app downloaded from Xiaomi servers, dug into them, and summarized what he found.

Scooter app firmware update dialog, saying "New firmware update available. Update now?" — Confirming this update will indefinitely lock you out of any third-party OTA updates

Unlike many of the security measures we’ve seen lacking-by-design, this one secures the OTA firmware updates with what we would consider the industry standard – SHA256 hash with elliptic cryptography-backed signing. As soon as the first firmware version implementing signature checks is flashed into your scooter, it won’t accept anything except further firmware binaries that come with Xiaomi’s digital signature. Unless a flaw is found in the signature checking implementation, the “flash a custom firmware with a smartphone app” route no longer seems to be a viable pathway for modding your scooter in ways Xiaomi doesn’t approve of.

Having disassembled the code currently available, [Daljeet] tells us about all of this – and more. In his extensive writeup, he shares scripts he used on his exploration journey, so that any sufficiently motivated hacker can follow in his footsteps, and we highly recommend you take a look at everything he’s shared. He also gives further insights, explaining some constraints of the OTA update process and pointing out a few security-related assumptions made by Xiaomi, worth checking for bypassing the security implemented. Then, he points out the firmware filenames hinting that, in the future, the ESC (Electronic Speed Control, responsible for driving the motors) board firmware might be encrypted with the same kind of elliptic curve cryptography, and finds a few update hooks in the decompiled code that could enable exactly that in future firmware releases.

One could argue that these scooters are typically modified to remove speed limits, installed there because of legal limitations in a variety of countries. However, the legal speed limits are more nuanced than a hard upper boundary, and if the hardware is capable of doing 35km/h, you shouldn’t be at mercy of Xiaomi to be able to use your scooter to its full extent where considerate. It would be fair to assert, however, that Xiaomi did this because they don’t want to have their reputation be anywhere near “maker of scooters that people can modify to break laws with”, and therefore we can’t expect them to be forthcoming.

Furthermore, of course, this heavily limits reuse and meaningful modification of the hardware we own. If you want to bring a retired pay-to-ride scooter back to usefulness, add Bluetooth, or even rebuild the scooter from the ground up, you should be able to do that. So, how do we go around such restrictions? Taking the lid off and figuring out a way to reflash the firmware through SWD using something like a Pi Pico, perhaps? We can’t wait to see what hackers figure out.

Picture of the setup described in the article, with PCI-E cards strewn around the desk, all interconnected, and a powered-up laptop, a large TV screen behind the laptop

This Laptop Gets All The PCIe Devices

April 20, 2022 by Arya Voronova 11 Comments

Did you ever feel like your laptop’s GPU was sub-optimal, or perhaps that your laptop could use a SAS controller? [Rob Rogers] felt like that too, so now he has the only Dell Latitude business-class laptop that’s paired with an AMD RX580 GPU – and more. Made possible because of a PCIe link he hijacked from the WiFi card, he managed to get a SAS controller, a USB 3.0 expansion card, the aforementioned GPU and a dual-port server network adapter, all in a single, desk-top setup, as the video demonstrates.

First off, we see a PCIe packet switch board based on a PLX-made chip, wrapped in blue tape, splitting a single PCIe x1 link into eight. The traditional USB 3.0 cables carry the downstream x1 links to the four PCIe cards connected, all laid out on [Rob]’s desk. [Rob] demonstrates that all of the cards indeed function correctly – the SAS controller connected to a server backplane with whole 22 TB of storage in it, a few devices plugged into a USB 3.0 card, an Ethernet cable with an active link in the network card, and wrapping up the video showing 3DMark results of the RX580 clearly paired with the laptop’s mobile CPU. There’s four more spots on the PCIe switch card, so if you wanted to connect a few NVMe SSDs without the costly USB enclosures that usually entails, you absolutely could!

Now, there’s a reason why we don’t see more of such hacks. This seems to be a Latitude E5440 and the card is plugged into a mini-PCIe slot, which means the entire contraption is bound by a single PCI-E Gen2 x1 link, heavily offsetting the gains you’d get from an external GPU when, say, gaming. However, when it comes to the types and amount of peripherals, this is unbeatable – if you want to add an external GPU, high-speed networking and a SAS controller to the same computer that you usually lug around, there isn’t really a dock station you can buy for that!

Our collection of cool PCIe hacks has been growing, with hackers adding external GPUs through ExpressCard and mini PCIe alike, fitting PCIe slots where the factory refused to provide one, and extending the onboard M.2 slots for full-size PCIe cards. Nowadays, with these packet switches, it’s easy as ever to outfit any PCIe capable device with a whole slew of features – as this Raspberry Pi Computer Module motherboard with eleven PCIe slots demonstrates. Wonder how PCIe works, and why all of that is possible? We’ve written an entire article on that!

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PicoCat, printed in yellow filament, looking at you with its ultrasonic sensor eyes

Build Your Own Cat – Some Assembly Required

April 18, 2022 by Arya Voronova 4 Comments

Robotic pets are sci-fi material, and [Kevin McAleer] from [Kev’s Robots] is moving us all ever so closer towards a brighter, happier, more robotic future. One of his latest robot builds, PicoCat, is a robot cat with servo-driven paws. It follows in the footsteps of the OpenCat project made by Dr. Rongzhong Li back in 2016, and we’re always happy seeing someone pick up where another hacker left off. [Kevin] took heavy inspiration from the OpenCat design – rebuilding it with hardware more friendly and accessible for makers today.

Projects like these, involving data processing and calculations to get the servos moving just right, stand to benefit from the computing power of recently released RP2040 MCU. As such, the Pimoroni Servo 2040 board is a crucial component of this build, being both the brains of the project and also a PIO-boosted driver for the eleven servos helping this robot come alive. This cat’s eyes are an ultrasonic sensor, and you can add a whole lot more sensors for any robotic intention of yours. Don’t expect this kitty to jump one meter high or scratch your favourite couch to death just yet, but there’s already a lot of potential, especially coupled with a small speaker.

Does this robotic cat interest you, whether it’d be due to your sci-fi propensity or a cat hair allergy? You’re in luck, because [Kevin] is keeping things firmly in the “open-source everything” realm. MicroPython code is stored in a GitHub repo, STLs are in a .zip linked on the page, and there’s plenty of renders to never leave you confused on what goes where. With all these resources, you can source the servos and the boards, fire up your 3D printer and sit down to assemble your own PicoCat. But not just that, [Kevin] also recorded three whole streams with insights, giving us over four hours of how-it-came-to-be video material for us to learn from. First, two streams of him designing the PicoCat in Fusion360, and then, him talking about the way he creates unit tests in MicroPython to improve his robots’ reliability and significantly reduce the amount of bugs cropping up.

This is not the last we will hear from [Kevin]’s robot-filled workshop, and previously, we’ve covered his Cray-1-shaped Pi Zero cluster system and a Raspberry Pi theremin, both as open and reproducible as this kitty! As you assemble yourself a PicoCat, or perhaps a Stanford Pupper or any of the other lovely quadru-pets we’ve previously featured, you might wonder how to properly move the servos, and we’ve covered a project that teaches you specifically that.

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