Oreo Construction: Hiding Your Components Inside The PCB

January 18, 2019 by Brian Benchoff 73 Comments

In recent months, the ability to hide components inside a circuit board has become an item of interest. We could trace this to the burgeoning badgelife movement, where engineers create beautiful works of electronic art. We can also attribute this interest to Bloomberg’s Big Hack, where Jordan Robertson and Michael Riley asserted Apple was the target of Chinese spying using components embedded inside a motherboard. The Big Hack story had legs, but so far no evidence of this hack’s existence has come to light, and the companies and governments involved have all issued denials that anything like this exists.

That said, embedding components inside a PCB is an interesting topic of discussion, and thanks to the dropping prices of PCB fabrication (this entire project cost $15 for the circuit boards), it’s now possible for hobbyists to experiment with the technique.

But first, it’s important to define what ‘stuffing components inside a piece of fiberglass’ is actually called. My research keeps coming back to the term ’embedded components’ which is utterly ungooglable, and a truly terrible name because ’embedded’ means something else entirely. You cannot call a PCB fabrication technique ’embedded components’ and expect people to find it on the Internet. For lack of a better term, I’m calling this ‘Oreo construction’, because of my predilection towards ‘stuf’, and because it needs to be called something. We’re all calling it ‘Oreo construction’ now, because the stuf is in the middle. This is how you do it with standard PCB design tools and cheap Chinese board houses.

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Ben Heck Can Program The Smallest Microcontroller

January 18, 2019 by Brian Benchoff 57 Comments

Microcontrollers are small, no one is arguing that. On a silicon wafer the size of a grain of rice, you can connect a GPS tracker to the Internet. Put that in a package, and you can put the Internet of Things into something the size of a postage stamp. There’s one microcontroller that’s smaller than all the others. It’s the ATtiny10, and its brethren the ATtiny4, 5, and 9. It comes in an SOT-23-6 package, a size that’s more often seen in packages for single transistors. It’s not very capable, but it is very small. It’s also very weird, with a programming scheme that’s not found in other chips from the Atmel/Microchip motherbrain. Now, finally, we have a great tutorial on using the ATtiny10, and it comes from none other than [Ben Heck].

The key difference between the ATtiny10 and other AVRs is that the tiny10 doesn’t use the standard AVR ISP protocol for programming. Instead of six pins for power, ground, MISO, MOSI, SCK, and RST, this is a high-voltage programming scheme that needs 12 Volts. The normal AVR programmer can do it, but you need to build an adapter. That’s exactly what [Ben] did, using a single-sided perf board, a lot of solder, and some headers. It looks like a lot, but there’s really not much to this programmer board. There’s a transistor and an optocoupler. The only thing that could make this programmer better is an SOT-23 ZIF socket. This would allow bare tiny10s to be programmed without first soldering them to a breakout board, but ZIF sockets are expensive to begin with, and the prices on SOT-23 sockets are absurd.

Programming the device was a matter of loading Atmel Studio and going through the usual AVR rigamarole, but Ben was eventually able to connect a light sensor to the tiny10 and have it output a value over serial. This was all done on a device with only 32 Bytes of RAM. That’s impressive, and one of the cool things about the smallest microcontroller you can buy.

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Brush With The Power Of 3D Printing

January 16, 2019 by Brian Benchoff 23 Comments

When it comes to 3D printing, functional prints are still few and far between. Sure, you can print a mount for anything, a Raspberry Pi case, but there are few prints out there that are truly useful, and even fewer that are useful while taking advantage of the specific capabilities of a 3D printer.

The Bouldering Brush from Turbo SunShine turns this observation on its head. It’s a useful device for getting the grime, sand, and sweat out of handholds while rock climbing, and it’s entirely 3D printed using manufacturing techniques only 3D printers can do.

If you’re thinking you’ve seen something like this technique before, you’re correct. The Hairy Lion from [_primoz_] on Thingiverse used a fine mesh of bridging to create small fibers of filament emanating from the mane of a lion. While it’s not a gender-neutral print, this is one of the first objects to make it to Thingiverse that truly showcased the sculptural element of many thin fibers of 3D printed filament. With this Bouldering Brush, these fibers become much more useful and even functional. It’s still a great technique, and if you can get your printer set up correctly and the settings correct, this is an awesome print that will easily demonstrate the capabilities of your printer.

Like the Hairy Lion, the Bouldering Brush is two handles that are mostly solid, and fine filaments of extruded plastic connecting these handles. Take the completed print off the bed , cut down the middle of the bristles, and you have a functional, completely 3D printed brush. Just don’t brush your teeth with it.

The Printed Solution To A Handful Of Resistors

January 16, 2019 by Brian Benchoff 44 Comments

Resistors are an odd bunch. Why would you have 1.0 Ω resistors, then a 1.1 Ω resistor, but there’s no resistors in between 4.7 Ω and 5.6 Ω? This is a question that has been asked for decades, but the answer is actually quite simple. Resistors are manufactured according to their tolerance, not their value. By putting twenty four steps on a logarithmic scale, you get values that, when you take into account the tolerance of each resistor, covers all possible values. Need a 5.0 Ω resistor? Take a meter to some 4.7 Ω and 5.6 Ω resistors. You’ll find one eventually.

As with all resistor collections, the real problem is storage. With SMD resistors you can stack your reels in stolen milk crates, but for through hole resistors, you’ll need some bins. [FerriteGiant] over on Thingiverse did just that. It’s a 3D printable enclosure that takes all of your E24 series resistors.

The design of this resistor storage solution is a bit like those old wooden cases full of index cards at that building where you can rent books for free. Or, if you like, a handy plastic small parts bin from Horror Fraught. The difference here is that these small cases are designed for the standard length of through-hole resistors, and each of the bins will hold a small 3D printed plaque telling you the value in each bin.

While this is a print that will take a lot of time — [FerriteGiant] spent 100 hours printing everything and used two kilograms of filament — it’s not like through-hole resistors are going away anytime soon. This is a project that you can build and have for the rest of your life, safely securing all your resistors in a fantastic box for all time.

New Part Day: SMD Batteries

January 16, 2019 by Brian Benchoff 60 Comments

Here’s a tip for all you retrocomputing enthusiasts or even anyone with an old computer in the garage. Go remove the battery. Yes, that old mid-90s desktop has a battery inside for the real-time clock, and it’s a ticking time bomb. Batteries leak, and they’ll spew goo all over the circuit board, irreparably damaging your piece of electronic nostalgia. This goes for all electronics, too: that badge collection is going to be a pile of broken fiberglass in a decade. Remove your batteries now.

While lithium cells soldered to a motherboard will leak, now there might be a new technology that will allow our modern electronics to last for decades. It’s a solid state battery. The FDK Corporation is now handing out samples of a battery that looks like a large SMD cap. They come on tape and reel, and they’ll never leak.

Thanks to massive investments in battery research, batteries are getting more power-dense, and form factors are getting weird. Your AirPods need a battery somewhere, and manufacturers are figuring out the best way to put a battery into something that can be assembled by a pick and place machine. This battery is the answer to these problems, packing a 3.0 V, 140 μAh lithium cobalt pyrophosphate cell into a package that is just 4 mm by 2 mm by 2 mm. It’s a battery that looks a surface mount component, and it’s installed the same way: this is a pick-and-placeable battery.

While the capacity of this battery is tiny — a 1225 coin cell has a capacity of about 50 mAh, and this battery has a capacity of 140 μAh, three whole orders of magnitude smaller — sometimes that’s all you need. If you need a battery for a RTC, this SMD battery will work.

3D Printing An Entire Rocket

January 14, 2019 by Brian Benchoff 43 Comments

If you’re ever flying into LAX and have the left side window seat, just a few minutes before landing, look out the window. You’ll see a small airport just below you and what appears at first glance to be a smokestack. That’s not a smokestack, though: that’s a rocket, and that’s where SpaceX is building all their rockets. Already SpaceX has revolutionized the aerospace industry, but just down the street there’s another company that’s pushing the manufacturing of rocket engines a bit further. Relativity Space is building rockets. They’re 3D printing rocket engines, and they’re designing what could be the first rocket engine made on Mars.

Bryce Salmi is an avionics hardware engineer at Relatively Space, and he made it out to the 2018 Hackaday Superconference to tell us all about manufacturing rockets. It’s an entirely new approach to manufacturing rockets and rocket engines with a clean-slate design that could eventually be manufactured on Mars.

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Hackaday Links: CES Is Over

January 13, 2019 by Brian Benchoff 17 Comments

CES is over, and once again we have proof technology does not improve our lives. Here’s the takeaway from the @internetofshit. There’s a garbage can where you can drop your DNA sample. This is obviously not a Bay Area startup, because they just leave DNA samples on the sidewalk there. The ‘smart cooler’ market is heating up (literally) with a cooler that’s also a grill. Someone duct taped an air filter to a roomba, so your air filter can go to where all the dirty air is in your house. Internet of Rubik’s Cubes. The world’s first autonomous shower made an appearance. Now you can take a shower over the Internet. What a time to be alive.

Need some more bad news from CES? We have more proof the entire tech industry is astonishingly sexist. How so? Well, VR sex simulators can win best of show. That’s a given, obviously. But a ‘smart’ sex toy designed by and for women was selected for a CES 2019 Innovation Award in the Robotics and Drone category. This award was given, then rescinded, by the Consumer Technology Association (CTA) because it was, ‘immoral, obscene, indecent, profane or not in keeping with the CTA’s image’. We presume they mean the latter, but we’re not sure.

Sometimes, though, there are actual engineers behind some of the gadgets on display at CES. Bell (yes, the aerospace company) unveiled the Bell Nexus, a five-seat VTOL ‘taxi’ powered by six ducted fans. These fans are powered by a hybrid electric power system. We assume a turboshaft connected to a generator powering electric motors. Most interestingly, speculation is that this will be the vehicle Uber’s Elevate air taxi program. This initiative by Uber intends to turn a random parking lot in LA into the busiest airport in the world. This is what the official marketing material from Uber says, I am not making this up, and it’s beyond stupid. You know what, just have Uber buy the Santa Monica airport, close it down, and turn it into an air taxi hub. This is the dumbest and funniest possible future imaginable.

Okay, CES is terrible, but here’s something for you. You can get a free ‘maker license’ of Solidworks. Just go here and enter promo code ‘918MAKER’. This info comes from reddit.

The Impossible Project was founded in 2008 as an initiative to remanufacture Polaroid film and refurbish cameras. The project was a rousing success with many supporters. It is a beacon of hope for anyone who wants to keep obsolete formats alive. Now, another format will live on. MacEffects, a company (or eBay store) in Indiana is remanufacturing color ribbons for Apple ImageWriter II printers. The ImageWriter II was the dot-matrix printer in your elementary school’s computer lab if you’re in the Oregon Trail generation, and yes, it could print color pictures. It could print very high-quality color pictures. The problem is getting color ribbons, and now you can get new ones. We’re very interested in seeing the art that can be made with a color ribbon in an ImageWriter, so if you have a portfolio, send it on in. If you have an ImageWriter, try to print something. It’s a serial printer, not a parallel printer.