Hacker Tactic: Multi-Design Panels

July 29, 2024 by Arya Voronova 12 Comments

Last time, we talked about single-PCB-design panels, all the cool aspects of it, including some cost savings and handling convenience. Naturally, you might wonder, and many did – can you put multiple different PCBs on a single panel? The answer is “yes, without a doubt!” The tool we used last time, KiKit, will not be as helpful here, so we’ll be looking elsewhere.

Making multi-PCB panels can help you save money, naturally, but it can also make your assembly a whole lot easier, and it can bring you hacking to a whole new level. It sure helped with mine! You might have already learned that some fabs scoff at multi-design panels and add surcharges. Well, you’ll be delighted to learn that there are more hacker-friendly fabs out there, too.

Developing PCBs In Bulk

So far, I’ve worked on about 300 different PCB designs, with half of them available in my monorepo. I’ve assembled and tested just about half of these. You might guess that this would cost a lot of money, and that assembly would take a fair bit of time, but I have some tricks up my sleeve. For a start, you can easily order PCBs 10-12 times more cheaply if you do multi-panel.

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Hacker Tactic: Single-PCB Panels

July 17, 2024 by Arya Voronova 35 Comments

Ordering a PCB? Two of them? Three? Five? For about eight years now, I’ve been regularly ordering large numbers of different PCBs, and, naturally, have developed a toolkit to make things smoother. One trick is PCB panelization, and you should really know about it.

You might’ve encountered PCB panels already. Perhaps, if you order PCBA at a fab, you will get your board returned in a whole new form-factor, with rails on the sides that you have to snap off before your PCB is usable. Those rails are used so that your PCBs are easier to handle during assembly, but that’s far from the only reason why you would make a panel.

If you need multiple pieces of a PCB, your fab may say that building 50 pcs is classified as “large batch” and that takes longer than 30 days, which delays your entire PCB order. I’ve been there, five years ago, running out of time right before Chinese New Year. The fix was simple – I made a 2×2 panel and ordered that in quantity of 10-15. Panelization might be a little more expensive, or maybe even cheaper, but, most importantly, it will be faster.

In a few hours’ time, I sat down, figured out that KiCad has built-in features for panelization, and ordered panels instead of separate PCBs. Thanks to that, I made the Chinese New Year deadline that year and could successfully restock my store, letting me earn a fair bit of money instead of keeping a popular product out-of-stock – ultimately, helping my family stay up on rent that month.

Panelization lets you hack around many PCB ordering and assembly limitations, and I’ve only gotten started – there’s way way more! For now, let’s sort out panelizing multiples of the same PCB. As long as your boards are using KiCad (or KiCad-converted from Eagle/EasyEDA/Altium/gerbers), there’s no better software than KiKit.

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Embedded Python: MicroPython Is Amazing

July 11, 2024 by Arya Voronova 105 Comments

In case you haven’t heard, about a month ago MicroPython has celebrated its 11th birthday. I was lucky that I was able to start hacking with it soon after pyboards have shipped – the first tech talk I remember giving was about MicroPython, and that talk was how I got into the hackerspace I subsequently spent years in. Since then, MicroPython been a staple in my projects, workshops, and hacking forays.

If you’re friends with Python or you’re willing to learn, you might just enjoy it a lot too. What’s more, MicroPython is an invaluable addition to a hacker’s toolkit, and I’d like to show you why. Continue reading “Embedded Python: MicroPython Is Amazing” →

PCB Design Review: HAB Tracker With ATMega328P

July 10, 2024 by Arya Voronova 15 Comments

Welcome to the Design Review Central! [VE3SVF] sends us their board, and it’s a HAB (High Altitude Balloon) tracker board. It’s got the venerable ATMega28P on it, a LoRa modem and a GPS module, and it can be powered from a LiIon battery. Stick this board with its battery onto a high-altitude balloon, have it wake up and transmit your coordinates every once in a while, and eventually you’ll find it in a field – if you’re lucky. Oherwise, it will get stuck hanging on a tree branch, and you will have to use a quadcopter to try and get it down, and then, in all likelihood, a second quadcopter so that you can free the first one. Or go get a long ladder.

The ATMega328P is tried and true, and while it’s been rising in price, it’s still available – with even an updated version that sports a few more peripherals; most importantly, you’re sure to find a 328P in your drawer, if not multiple. Apart from that, the board uses two modules from a Chinese manufacturer, G-Nice, for both GPS and Lora. Both of these modules are cheap, making this tracker all that more accessible; I could easily see this project being sold as a “build your own beacon” kit!

Let’s make it maybe a little nicer, maybe a little cheaper, and maybe decrease the power consumption a tad along the way. We’ll use some of the old tricks, a few new ones, and talk about project-specific aspects that might be easy to miss.

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Hack All The Things, Get All The Schematics

July 8, 2024 by Arya Voronova 32 Comments

When I was growing up, about 4 or 5 years old, I had an unorthodox favourite type of reading material: service manuals for my dad’s audio equipment. This got to the point that I kept asking my parents for more service manuals, and it became a running joke in our family for a bit. Since then, I’ve spent time repairing tech and laptops in particular as a way of earning money, hanging out at a flea market in the tech section, then spending tons of time at our hackerspace. Nowadays, I’m active in online hacker groups, and I have built series of projects closely interlinked with modern-day consumer-facing tech.

Twenty three years later, is it a wonder I have a soft spot in my heart for schematics? You might not realize this if you’re only upcoming in the hardware hacking scene, but device schematics, whichever way you get them, are a goldmine of information you can use to supercharge your projects, whether you’re hacking on the schematic-ed device itself or not. What’s funny is, not every company wants their schematics to be published, but it’s ultimately helpful for the company in question, anyway.

If you think it’s just about repair – it’s that, sure, but there’s also a number of other things you might’ve never imagined you can do. Still, repair is the most popular one.
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USB And The Myth Of 500 Milliamps

July 3, 2024 by Arya Voronova 92 Comments

If you’re designing a universal port, you will be expected to provide power. This was a lesson learned in the times of LPT and COM ports, where factory-made peripherals and DIY boards alike had to pull peculiar tricks to get a few milliamps, often tapping data lines. Do it wrong, and a port will burn up – in the best case, it’ll be your port, in worst case, ports of a number of your customers.

Want a single-cable device on a COM port? You might end up doing something like this.

Having a dedicated power rail on your connector simply solves this problem. We might’ve never gotten DB-11 and DB-27, but we did eventually get USB, with one of its four pins dedicated to a 5 V power rail. I vividly remember seeing my first USB port, on the side of a Thinkpad 390E that my dad bought in 2000s – I was eight years old at the time. It was merely USB 1.0, and yet, while I never got to properly make use of that port, it definitely marked the beginning of my USB adventures.

About six years later, I was sitting at my desk, trying to build a USB docking station for my EEE PC, as I was hoping, with tons of peripherals inside. Shorting out the USB port due to faulty connections or too many devices connected at once was a regular occurrence; thankfully, the laptop persevered as much as I did. Trying to do some research, one thing I kept stumbling upon was the 500 mA limit. That didn’t really help, since none of the devices I used even attempted to indicate their power consumption on the package – you would get a USB hub saying “100 mA” or a mouse saying “500 mA” with nary an elaboration.

Fifteen more years have passed, and I am here, having gone through hundreds of laptop schematics, investigated and learned from design decisions, harvested laptops for both parts and even ICs on their motherboards, designed and built laptop mods, nowadays I’m even designing my own laptop motherboards! If you ever read about the 500 mA limit and thought of it as a constraint for your project, worry not – it’s not as cut and dried as the specification might have you believe.
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The ring shown on someone's index finger

The ErgO Ring Makes Computer Interactions Comfortable

July 3, 2024 by Arya Voronova 6 Comments

[Sophia Dai] brings us a project you will definitely like if you’re tired of traditional peripherals like a typical keyboard and mouse combo. This is ErgO, a smart ring you can build out of a few commonly available breakouts, and it keeps a large number of features within a finger’s reach. The project has got an IMU, a Pimoroni trackball, and a good few buttons to perform actions or switch modes, and it’s powered by a tiny Bluetooth-enabled devboard so it can seamlessly perform HID device duty.

While the hardware itself appears to be in a relatively early state, there’s no shortage of features, and the whole experience looks quite polished. Want to lay back in your chair yet keep scrolling the web, clicking through links as you go? This ring lets you do that, no need to hold your mouse anymore, and you can even use it while exercising. Want to do some quick text editing on the fly? That’s also available; the ErgO is designed to be used for day to day tasks, and the UX is thought out well. Want to use it with more than just your computer? There is a device switching feature. The build instructions are quite respectable, too – you can absolutely build one like this yourself, just get a few breakouts, a small battery, some 3D printed parts, and find an evening to solder them all together. All code is on GitHub, just like you would expect from a hack well done.

Looking for a different sort of ring? We’ve recently featured a hackable cheap smart ring usable for fitness tracking – this one is a product that’s still being reverse-engineered, but it’s alright if you’re okay with only having an accelerometer and a few optical sensors.

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