Author: Bryan Cockfield

1761 Articles

DIY Laser For Ablating Metal

July 17, 2023 by 51 Comments

For those who wish to go beyond through-hole construction on perfboard for their circuit boards, a printed circuit board is usually the next step up. Allowing for things like surface-mount components, multi-layer boards, and a wider array of parts, they are much more versatile but do have a slight downside in that they are a little bit harder to make. There are lots of methods for producing them at home or makerspace, though, and although we’ve seen plenty of methods for their production like toner transfer, photoresist, and CNC milling, it’s also possible to make them using laser ablation, although you do need a special laser to get this job done.

The problem with cutting copper is that it reflects infra-red, so a higher-wavelength blue green laser is used instead. And because you want to ablate the copper, but not melt the surrounding areas or cut straight through the board, extremely short, high-power pulses are the way to go. Here, the [Munich Fab Lab] is using 9 kW pulses of around 30 microseconds each.  With these specifications the copper is ablated from the surface of the board allowing for fine details in the range of about 20 µm, which is fine enough for just about any circuit board. The design of the laser head itself is worth a look.

Aside from the laser, the rest is standard CNC machine fodder, but with an emphasis on safety that’s appropriate for a tool in a shared workspace, and the whole project is published under an open license and offers an affordable solution for larger-scale PCB production with extremely fine resolution and without the need for any amounts of chemicals for the more common PCB production methods. There is a lot more information available on the project’s webpage and its GitHub page as well.

Of course, there are other methods of producing PCBs by laser if you happen to have a 20 W fiber laser just kicking around.

Reverse Engineering A Classic ThinkPad Battery

July 15, 2023 by 14 Comments

The ThinkPad 701 is an iconic laptop series from the mid-90s and is still highly sought after today because of its famous butterfly keybaord. The laptop itself is tiny even by the standards of the time, so in order to fit a full-size keyboard IBM devised a mechanism where the keyboard splits and slides over itself to hide away as the screen is closed. But, like most 30-year-old laptops, the original batteries for these computers are well past their prime. [polymatt] takes us through all of the steps needed in order to recreate a battery from this era down to the last detail.

He starts by disassembling an old battery with extensive damage from the old, leaky batteries. The first part of the recreation is to measure the battery casing so a new one can be modeled and printed. The control boards for the batteries of these computers were not too sophisticated, so [polymatt] is able to use a logic analyzer with a working unit to duplicate its behavior on an ATtiny microcontroller. With that out of the way, a new PCB is created to host the cloned chip and a new battery pack, made out of 9 NiMH cells is put together.

[polymatt] wanted this build to be as authentic as possible, so he even goes as far as replicating the label on the underside of the battery. With everything put together he has a faithful recreation of this decades-old battery for a famous retro laptop. ThinkPads are popular laptops in general, too, due to their fairly high build quality (at least for their enterprise lineups) and comprehensive driver support especially for Linux and other open-source software projects like coreboot and libreboot.

Thanks to [Roman UA] for the tip!

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Trebuchet Sends Eggs Flying

July 14, 2023 by 7 Comments

Without any sort of restrictions on designs for trebuchets, these medieval siege weapons are known to send 90 kilogram projectiles over 300 meters. The egg-launching trebuchet contest that [AndysMachines] is entering, on the other hand, has a few limitations that dramatically decreased the size of the machines involved. The weight of the entire device is limited to no more than 3 kg, with any physical dimension no more than 300 mm, but that’s more than enough to send an egg flying across a yard with the proper design and tuning for maximum distance.

Trebuchets distinguish themselves amongst other siege weapons by using a falling weight to launch the projectile. The rules of this contest allow for the use of springs, so [AndysMachines] is adding a spring in between the trebuchet arm and the weight in order to more efficiently deliver the energy from the falling weight. More fine tuning of the trebuchet was needed before the competition, though, specifically regarding the stall point for the trebuchet. This is the point where the forces acting on the arm from the projectile and the weight are balanced, and moving this point to allow the projectile to release at a 45-degree angle was needed for maximum distance.

The video goes into a lot of detail about other fine-tuning of a trebuchet like this, aided by some slow-motion video analysis. In the end, [AndysMachines] was able to launch the egg over ten meters with this design. Of course, if you want to throw out the rule book and replace the eggs with ball bearings and the aluminum and steel with titanium, it’s possible to build a trebuchet that breaks the sound barrier.

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Listening To Bats As They Search For Food

July 14, 2023 by 14 Comments

The range of human hearing goes up to about 20 kilohertz, which is fine for our purposes, but is pretty poor compared to plenty of other animal species. Dogs famously can hear up to about 60 kHz, and dolphins are known to distinguish sounds up to 100 kHz. But for extremely high frequencies we’ll want to take a step into the world of bats. Some use echolocation to locate each other and their food sources, and bats like the pipistrelle can listen in to sounds up to 350 kHz. To listen to them you’ll need a device like the π*pistrelle.

The original implementation of the bat detector was based on a Raspberry Pi Pico, from which it gets its name. But there have been several improvements on it in the years since it was first developed. The latest can detect bats when it hears their 350 kHz sonar calls thanks to an ultrasonic microphone and op amp. The device then records the bat sounds and then either heterodynes the sound down or time-expands it to human-audible range so the calls can actually be heard. There’s an LED display on the board as well as three input buttons, but an iOS companion app is available to interact with the device as well.

If you want to know for sure which species is flying around at night, you can use machine learning to help figure that out.

Taking Mechanical Keyboard Sounds To The Next Level

July 13, 2023 by 10 Comments

When it comes to mechanical keyboards, there’s no end to the amount of customization that can be done. The size and layout of the keyboard is the first thing to figure out, and then switches, keycaps, and then a bunch of other customizations inside the keyboard like the mounting plate and whether or not to add foam strips and other sound- and vibration-deadening features. Of course some prefer to go the other direction with it as well, omitting the foam and installing keys with a more noticeable click, and still others go even further than that by building a separate machine to make their keyboard activity as disruptive as it could possibly be.

This started as a joke among [ac2ev] and some coworkers, who were already teasing about the distinct sound of the mechanical keyboard. This machine, based on a Teensy microcontroller, sits between any USB keyboard and its host computer, intercepting keystrokes and using a small solenoid to tap on a block of wood every time a keystroke is detected. There’s also a bell inside that rings when the enter key is pressed, similar to the return carriage notification for typewriters, and as an additional touch an audio amplifier with attached speaker plays the Mario power-up sound whenever the caps lock key is pressed.

[ac2ev] notes that this could be pushed to the extreme by running a much larger solenoid powered by mains electricity, but since this was more of a proof-of-concept demonstration for some coworkers the smaller solenoid was used instead. The source code for the build can be found on the project’s GitHub page and there’s also a video of this machine in action here as well. Be careful with noisy mechanical keyboards, though, as the sounds the keys produce can sometimes be decoded to determine what the user is typing.

Timekeeping For Distributed Computers

July 13, 2023 by 14 Comments

Ask any programmer who has ever had to deal with timekeeping on a computer, and they’re likely to go on at length about how it can be a surprisingly difficult thing to keep track of. Time zones, leap years, leap seconds, various timekeeping standards, clock drift, and even relativity are all problems that can creep in to projects. Issues with timekeeping are exacerbated in distributed systems as well, adding another layer of complexity when we need to reliably determine the order that a series of actions occurred across a number of different computers with a high precision. One solution to this problem is the implementation of a vector clock.

When using other systems such as logical clocks to attempt to keep track of the order of events on different computers, a problem that may arise is that these systems don’t always track these changes with perfect reliability due to many issues such as varying temperature, race conditions, or clock skew. The vector clock instead tracks causal relationships between events. Each separate process maintains its own vector clock, represented by a list of integers. When one of these processes performs an event, it increments its own clock and sends it out to the rest of the system. By keeping track of this clock as it is updated by various processes across the computer the distributed system can be much more confident about the order in which events took place.

Of course, there are always downsides with elegant solutions like this. In the case of vector clocks the downside is largely increased overhead for keeping track of all of the sets of integers. But in systems where the ordering of processes is of the upmost importance, this is worth the trade-off to ensure reliability. And unless we hook all of our computers up to atomic clocks like they do for some computers at CERN we will have to take the increased overhead instead.

Recreating The Golden Era Of Cable TV

July 13, 2023 by 55 Comments

Fewer and fewer people have cable TV subscriptions these days, due to a combination of poor business practices by cable companies and the availability of alternatives to cable such as various streaming platforms. But before the rise of the Internet that enabled these alternatives, there was a short period of time where there were higher-quality channels, not too many commercials, a possibly rose-tinted sense of wonder, and where MTV actually played music. [Irish Craic Party] created this vintage cable TV network to capture this era of television history.

The hardware for this build is a Raspberry Pi driving an LCD display recovered from an old iPad. There’s a custom TV tuner which handles changing the channels and interfaces with an Apple Remote. Audio is sent through old computer speakers, and the case is built from 3D printed parts and some leftover walnut plywood to give it an era-appropriate 80s or early 90s feel. We’ve seen other builds like this before, but where this one really sets itself apart is in the software that handles the (television) programming.

[Irish Craic Party] has gone to great lengths here to recreate the feel of cable TV from decades ago. It has recreations of real channels like HBO, Nickelodeon, and FX including station-appropriate bumpers and commercials. It’s also synchronized to the clock so shows start on the half- or quarter-hour. Cartoons play on Saturday morning, and Nickelodeon switches to Nick-at-Nite in the evenings. There are even channels that switch to playing Christmas movies at the appropriate times, complete with Christmas-themed commercials.

The build even hosts a preview channel, one of the more challenging parts of the build. It continually scrolls through the channels and shows what’s currently playing and what will be showing shortly, complete with a commercial block at the top. For those who were around in the 90s it’s almost a perfect recreation of the experience of watching TV back then. It can even switch to a video game input when tuned to channel 3. There’s almost too much to go into in a short write-up so be sure to check the video after the break.

Thanks to [PCrozier] for the tip!

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