Author: Dan Maloney

3271 Articles

From The Ashes: Coal Ash May Offer Rich Source Of Rare Earth Elements

March 19, 2025 by 16 Comments

For most of history, the world got along fine without the rare earth elements. We knew they existed, we knew they weren’t really all that rare, and we really didn’t have much use for them — until we discovered just how useful they are and made ourselves absolutely dependent on them, to the point where not having them would literally grind the world to a halt.

This dependency has spurred a search for caches of rare earth elements in the strangest of places, from muddy sediments on the sea floor to asteroids. But there’s one potential source that’s much closer to home: coal ash waste. According to a study from the University of Texas Austin, the 5 gigatonnes of coal ash produced in the United States between 1950 and 2021 might contain as much as $8.4 billion worth of REEYSc — that’s the 16 lanthanide rare earth elements plus yttrium and scandium, transition metals that aren’t strictly rare earths but are geologically associated with them and useful in many of the same ways. Continue reading “From The Ashes: Coal Ash May Offer Rich Source Of Rare Earth Elements” →

Ask Hackaday: What Would You Do With The World’s Smallest Microcontroller?

March 17, 2025 by 89 Comments

It’s generally pretty easy to spot a microcontroller on a PCB. There are clues aplenty: the more-or-less central location, the nearby crystal oscillator, the maze of supporting passives, and perhaps even an obvious flash chip lurking about. The dead giveaway, though, is all those traces leading to the chip, betraying its primacy in the circuit. As all roads lead to Rome, so it often is with microcontrollers.

It looks like that may be about to change, though, based on Texas Instruments’ recent announcement of a line of incredibly small Arm-based microcontrollers. The video below shows off just how small the MSPM0 line can be, ranging from a relatively gigantic TSSOP-20 case down to an eight-pin BGA package that measures only 1.6 mm by 0.86 mm. That’s essentially the size of an 0603 SMD resistor, a tiny footprint for a 24-MHz Cortex M0+ MCU with 16-kB of flash, 1-kB of SRAM, and a 12-bit ADC. The larger packages obviously have more GPIO brought out to pins, but even the eight-pin versions support six IO lines.

Of course, it’s hard not to write about a specific product without sounding like you’re shilling for the company, but being first to market with an MCU in this size range is certainly newsworthy. We’re sure other manufacturers will follow suit soon enough, but for now, we want to know how you would go about using a microcontroller the size of a resistor. The promo video hints at TI’s target market for these or compact wearables by showing them used in earbuds, but we suspect the Hackaday community will come up with all sorts of creative and fun ways to put these to use — shoutout to [mitxela], whose habit of building impossibly small electronic jewelry might be a good use case for something like this.

There may even be some nefarious use cases for a microcontroller this small. We were skeptical of the story about “spy chips” on PC motherboards, but a microcontroller that can pass for an SMD resistor might change that equation a bit. There’s also the concept of “Oreo construction” that these chips might make a lot easier. A board with a microcontroller embedded within it could be a real security risk, but on the other hand, it could make for some very interesting applications.

What’s your take on this? Can you think of applications where something this small is enabling? Or are microcontrollers that are likely to join the dust motes at the back of your bench after a poorly timed sneeze a bridge too far? Sound off in the comments below.

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Hackaday Links: March 16, 2025

March 16, 2025 by 3 Comments

“The brickings will continue until the printer sales improve!” This whole printer-bricking thing seems to be getting out of hand with the news this week that a firmware update caused certain HP printers to go into permanent paper-saver mode. The update was sent to LaserJet MFP M232-M237 models (opens printer menu; checks print queue name; “Phew!) on March 4, and was listed as covering a few “general improvements and bug fixes,” none of which seem very critical. Still, some users reported not being able to print at all after the update, with an error message suggesting printing was being blocked thanks to non-OEM toner. This sounds somewhat similar to the bricked Brother printers we reported on last week (third paragraph).

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Building A Ten-Hundred Key Computer Word-Giving Thing

March 14, 2025 by 17 Comments

From the styling of this article’s title, some might assume that the Hackaday editors are asleep at the switch this fine day. While that might be true — it’s not our turn to watch them — others will recognize this tortured phrasing as one way to use the 1,000 most commonly used words in the English language to describe a difficult technical project, such as [Attoparsec]’s enormous and enormously impractical ten-hundred word keyboard.

While the scale of this build is overwhelming enough, the fact that each key delivers a full word rather than a single character kind of throws the whole keyboard concept out the window. The 60×17 matrix supports the 1,000 most common English words along with 20 modifier keys, which allow a little bit of cheating on the 1-kiloword dictionary by letting you pluralize a word or turn it into an adjective or adverb. Added complexity comes from the practical limits of PCB fabrication, which forces the use of smaller (but still quite large) PCBs that are connected together. Luckily, [Attoparsec] was able to fit the whole thing on five identical PCBs, which were linked together with card-edge connectors.

The list of pain points on this six-month project is long, and the video below covers them all in detail. What really stood out to us, though, was the effort [Attoparsec] put into the keycaps. Rather than 3D printing his own, he used dye sublimation to label blank keycaps with the 1,000 words. That might sound simple, but he had to go through a lot of trial and error before getting a process that worked, and the results are quite nice. Another problem was keeping the key switches aligned while soldering, which was solved with a 3D printed jig. We also appreciate the custom case to keep this keyboard intact while traveling; we’re going to keep that build-your-own road case service in mind for future projects.

This mega-keyboard is a significant escalation from [Attoparsec]’s previous large keyboard project. The results are pretty ridiculous and impractical, but that’s just making us love it more. The abundance of tips and tricks for managing a physically expansive project are just icing on the cake.

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The Mysterious And Important Work Of Prop Design On Severance

March 13, 2025 by 28 Comments

Have you seen Severance? Chances are good that you have; the TV series has become wildly popular in its second season, to the point where the fandom’s dedication is difficult to distinguish from the in-universe cult of [Kier]. Part of the show’s appeal comes from its overall aesthetic, which is captured in this description of the building of one of the show’s props.

A detailed recap of the show is impossible, but for the uninitiated, a mega-corporation called Lumon has developed a chip that certain workers have implanted in their brains to sever their personalities and memories into work and non-work halves. The working “Innies” have no memory of what their “Outies” do when they aren’t at work, which sounds a lot better than it actually ends up being. It’s as weird as it sounds, and then some.

The prop featured here is the “WoeMeter” from episode seven of season two, used to quantify the amount of woe in a severed worker — told you it was weird. The prop was built by design house [make3] on a short timeline and after seeing only some sketches and rough renders from the production designers, and had to echo the not-quite-midcentury modern look of the whole series. The builders took inspiration from, among other things, a classic Nagra tape recorder, going so far as to harvest its knobs and switches to use in the build. The controls are all functional and laid out in a sensible way, allowing the actors to use the device in a convincing way. For visual feedback, the prop has two servo-operated meters and a string of seven-segment LED displays, all controlled by an ESP-32 mounted to a custom PCB. Adding the Lumon logo to the silkscreen was a nice touch.

The prop maker’s art is fascinating, and the ability to let your imagination run wild while making something that looks good and works for the production has got to be a blast. [make3] really nailed it with this one.

Thanks to [Aaron’s Outie] for the tip.

Got Junk? Then Build This Scrappy TEA Laser

March 13, 2025 by 24 Comments

A piece of glass, some bits of tinfoil, a sheet of plastic, a couple of razor blades, and a few assorted bits and bobs are all it takes to build this TEA nitrogen laser. Oh, and a 5,000-volt flyback supply with enough amperage to stop your heart. You’ll need that too.

Seriously, if you choose to follow [MultiverseCurator] ‘s example and build this laser, you’ll want to take the proper precautions. A transversely excited atmospheric laser is simple in concept, but there are plenty of ways for them to go wrong. Unlike the gas lasers used in laser cutters, there’s no enclosed resonator cavity or mirrors. Rather, the excitation takes place across a narrow gap between two electrodes, using atmospheric nitrogen as the lasing medium. This results in hard UV emissions, which means you can’t see them with the naked eye. Add to that the spark gap creating extremely loud discharges as the laser operates, and hazards abound. Proceed with caution.

Construction starts with a flat glass plate and a pair of large capacitors made from aluminum foil plates separated by a plastic dielectric. The razor blades are connected across the capacitors, separated by a narrow gap, with an inductor made from magnet wire in parallel. A spark gap made from nuts and bolts goes in series, and the whole assembly gets connected to a high-voltage power supply — [Multiverse] used a ZVS driver and a CRT flyback transformer with an eight-megohm resistor in series. The video below has all the build details.

It’ll take a little fiddling to get it lasing, and you’ll need something phosphorescent to see the UV light — a scrap of copy paper should do. But the results are pretty amazing for something made from scrap. If you want to take the design to the next level, you’ll want to check out [Les Wright]’s TEA laser build.

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Classy Paper Tape Reader Complements Homebrew Retrocomputer

March 11, 2025 by 26 Comments

If you were one of the earliest of early adopters in the home computing revolution, you might have had to settle for paper tape mass storage. It was slow, it was bulky, but it was what you had, and that gave it a certain charm that’s hard to resist. And that charm is what [Joshua Coleman] captures with this DIY paper tape reader build.

If the overall style of this project looks familiar, it’s because it was meant to echo the design themes from [Joshua]’s Coleman Z-80 modular computer. The electronics of the reader are based on [David Hansel]’s take on a paper tape reader, which in turn was meant to complement his Altair 8080 simulator — it’s retrocomputers all the way down! [Joshua]’s build has a few bells and whistles to set it apart, though, including an adjustable read head, parametric 3D-printed reels, and a panel mounted ammeter, just because. He also set it up to be a sort of keyboard wedge thanks to an internal relay that bypasses the reader unless it’s actually playing back a tape. Playback speed is pretty fast; see the video below for details.

So far, writing the tapes is an offline process. [Joshua] uses a Python program to convert ASCII to an SVG file and uses a laser cutter to burn holes in lengths of paper, which are then connected together to form a longer tape. A logical next step might be to build a feeder that moves a paper tape across the bed of the laser cutter in sync with the conversion program, to create continuous paper tapes. Or, there’s always the old-school route of solenoid-powered punch and die. We’d be thrilled with either.

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