Author: Dan Maloney

3283 Articles

Get Your Glitch On With A PicoEMP And A 3D Printer

August 3, 2024 by 10 Comments

We’re not sure what [Aaron Christophel] calls his automated chip glitching setup built from a 3D printer, but we’re going to go ahead and dub it the “Glitch-o-Matic 9000.” Has a nice ring to it.

Of course, this isn’t a commercial product, or even a rig that’s necessarily intended for repeated use. It’s more of a tactical build, which is still pretty cool if you ask us. It started with a proof-of-concept exploration, summarized in the first video below. That’s where [Aaron] assembled and tested the major pieces, which included a PicoEMP, the bit that actually generates the high-voltage pulses intended to scramble a running microcontroller temporarily, along with a ChipWhisperer and an oscilloscope.

The trouble with the POC setup was that glitching the target chip, an LPC2388 microcontroller, involved manually scanning the business end of the PicoEMP over the package. That’s a tedious and error-prone process, which is perfect for automation. In the second video below, [Aaron] has affixed the PicoEMP to his 3D printer, giving him three-axis control of the tip position. That let him build up a heat map of potential spots to glitch, which eventually led to a successful fault injection attack and a clean firmware dump.

It’s worth noting that the whole reason [Aaron] had to resort to such extreme measures in the first place was the resilience of the target chip against power supply-induced glitching attacks. You might not need to build something like the Glitch-o-Matic, but it’s good to keep in mind in case you run up against such a hard target. Continue reading “Get Your Glitch On With A PicoEMP And A 3D Printer” →

Custom Hat Gives Vintage Mitutoyo Calipers A New Lease On Life

August 2, 2024 by 16 Comments

Metrology fans are usually at least a little bit in love with Mitutoyo, and rightfully so. The Japanese company has been making precision measuring instruments for the better part of 100 years, and users appreciate their precision almost as much as the silky smooth feel of their tools. If you can afford it, a Mitutoyo caliper is quite an addition to your toolbox.

As good as they are, though, they’re not perfect, which is what led to this clever Mitutoyo digital caliper hack by [turbanedengineer]. The calipers in question, a digital set from the early 1980s, happen to have a unique history with a tangential Hackaday angle — they belonged to [Dhaval], mechanical engineer and avid motorcyclist who happens to be the late elder brother of our own [Anool Mahidharia].

The tool, in need of a little TLC, made its way to [turbanedengineer] who first restored the broken battery contacts. Once powered up again, it became apparent that while the caliper’s native metric measurements were spot on, the internal conversion to inches was considerably off. This led [turbanedengineer] to the data port on the tool, which is intended to send serial data to an external computer for logging measurements. After a little experimentation to nail down the data format, he prototyped a tiny circuit using an ATtiny85 and an OLED display that reads the caliper data, converts metric to inches, and displays both measurements on the screen. The prototype led to a more permanent version, which cleverly sits over the original display and taps into the data port without any free wires. The video below shows the very slick results.

Our hearts go out to [Anool] and his family for their loss, and we tip our hats to [turbanedengineer] for his thoughtful and respectful hack of a storied tool. We know that anthropomorphizing tools makes no rational sense, but we think it’s safe to say that a tool like this has a soul, and it’s probably happy to be back in the game.

Continue reading “Custom Hat Gives Vintage Mitutoyo Calipers A New Lease On Life” →

Over-molding Wires With Hot Glue And 3D Printed Molds

August 2, 2024 by 50 Comments

We’ve said it before and we’ll say it again: water always finds a way in. That’s particularly problematic for things like wire splices in damp environments, something that no amount of electrical tape is going to help. Heat shrink tubing might be your friend here, but for an electrically isolated and mechanically supported repair, you may want to give over-molding with a hot glue gun a try.

The inspiration for [Print Practical]’s foray into over-molding came from a video that’s making the rounds showing a commercially available tool for protecting spliced wires in the automotive repair trade. It consists of a machined aluminum mold that the spliced wires fit into and a more-or-less stock hot glue gun, which fills the mold with melted plastic. [Print Practical] thought it just might be possible to 3D print custom molds at home and do it himself.

His first attempt didn’t go so well. As it turns out, hot glue likes to stick to things — who knew? — including the PETG mold he designed. Trying to pry apart the mold after injection was a chore, and even once he got inside it was clear the glue much preferred to stay in the mold. Round two went much better — same wire, same mold, but now with a thin layer of vegetable oil to act as a release agent. That worked like a charm, with the over-mold standing up to a saltwater bath with no signs of leaking. [Print Practical] also repaired an iPhone cable that has seen better days, providing much-needed mechanical support for a badly frayed section.

This looks like a fantastic idea to file away for the future, and one that’s worth experimenting with. Other filament types might make a mold better able to stand up to the hot glue, and materials other than the ethylene-vinyl acetate copolymer found in most hot glue sticks might be explored. TPU over-molds, anyone? Or perhaps you can use a printer as an injector rather than the glue gun.

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Programming Tiny Blinkenlight Projects With Light

August 1, 2024 by 18 Comments

[mitxela] has a tiny problem, literally: some of his projects are so small as to defy easy programming. While most of us would probably solve the problem of having no physical space on a board to mount a connector with WiFi or Bluetooth, he took a different path and gave this clever light-based programming interface a go.

Part of the impetus for this approach comes from some of the LED-centric projects [mitxela] has tackled lately, particularly wearables such as his LED matrix earrings or these blinky industrial piercings. Since LEDs can serve as light sensors, albeit imperfect ones, he explored exactly how to make the scheme work.

For initial experiments he wisely chose his larger but still diminutive LED matrix badge, which sports a CH32V003 microcontroller, an 8×8 array of SMD LEDs, and not much else. The video below is a brief summary of the effort, while the link above provides a much more detailed account of the proceedings, which involved a couple of false starts and a lot of prototyping that eventually led to dividing the matrix in two and ganging all the LEDs in each half into separate sensors. This allows [mitxela] to connect each side of the array to the two inputs of an op-amp built into the CH32V003, making a differential sensor that’s less prone to interference from room light. A smartphone app alternately flashes two rectangles on and off with the matrix lying directly on the screen to send data to the badge — at a low bitrate, to be sure, but it’s more than enough to program the badge in a reasonable amount of time.

We find this to be an extremely clever way to leverage what’s already available and make a project even better than it was. Here’s hoping it spurs new and even smaller LED projects in the future.

Continue reading “Programming Tiny Blinkenlight Projects With Light” →

Undersea Cable Repair

July 30, 2024 by 6 Comments

The bottom of the sea is a mysterious and inaccessible place, and anything unfortunate enough to slip beneath the waves and into the briny depths might as well be on the Moon. But the bottom of the sea really isn’t all that far away. The average depth of the ocean is only about 3,600 meters, and even at its deepest, the bottom is only about 10 kilometers away, a distance almost anyone could walk in a couple of hours.

Of course, the problem is that the walk would be straight down into one of the most inhospitable environments our planet has to offer. Despite its harshness, that environment is home to hundreds of undersea cables, all of which are subject to wear and tear through accidents and natural causes. Fixing broken undersea cables quickly and efficiently is a highly specialized field, one that takes a lot of interesting engineering and some clever hacks to pull off.

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Junk Bin Build Lets You Test Fuel Injectors On The Cheap

July 30, 2024 by 32 Comments

Fiddle around with cars long enough and you’ll realize two things: first, anything beyond the simplest repairs will probably require some kind of specialized tool, and second, those tools can be prohibitively expensive. That doesn’t mean you’re out of luck, though, especially if you’ve got scrap galore and a DIY spirit, as this junk bin fuel injector test stand ably demonstrates.

[Desert Rat Racer]’s test rig is designed to support four injectors at once and to test them under conditions as close as possible to what they’ll experience when installed. To that end, [Rat] mounted a junk intake manifold to a stand made from scrap wood and metal found by the side of the road. A pickle jar serves as a reservoir for the test fluid — he wisely used mineral spirits as a safer substitute for gasoline — and a scrap electric fuel pump pressurizes a junk fuel rail, which distributes fuel to the injectors under test.

For testing, the injectors are wired up to an electric injector tester, which is one of the few off-the-shelf components in the build. The fuel pump and injectors are powered by the 12 volt rail of a scrapped PC power supply. Just being able to watch the spray pattern is often enough to find a faulty injector, but in case a more quantitative test is indicated, each injector is positioned over a cheap glass cylinder to catch the test fluid, and scraps of a tape measure are used to measure the depth of the collected fluid. No fancy — and expensive — graduated cylinders required.

While we truly respect the hackiness of [Desert Rat Racer]’s build, the concept of avoiding buying tactical tools is foreign to us. We understand the logic of not dropping a ton on a single-use tool, but where’s the fancy blow-molded plastic case?

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Hackaday Links: July 28, 2024

July 28, 2024 by 14 Comments

What is this dystopia coming to when one of the world’s largest tech companies can’t find a way to sufficiently monetize a nearly endless stream of personal data coming from its army of high-tech privacy-invading robots? To the surprise of almost nobody, Amazon is rolling out a paid tier to their Alexa service in an attempt to backfill the $25 billion hole the smart devices helped dig over the last few years. The business model was supposed to be simple: insinuate an always-on listening device into customers’ lives to make it as easy as possible for them to instantly gratify their need for the widgets and whatsits that Amazon is uniquely poised to deliver, collecting as much metadata along the way as possible; multiple revenue streams — what could go wrong? Apparently a lot, because the only thing people didn’t do with Alexa was order stuff. Now Amazon is reportedly seeking an additional $10 a month for the improved AI version of Alexa, which will be on top of the ever-expanding Amazon Prime membership fee, currently at an eye-watering $139 per year. Whether customers bite or not remains to be seen, but we think there might be a glut of Echo devices on the second-hand market in the near future. We hate to say we told you so, but — ah, who are we kidding? We love to say we told you so.

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