Testing Oxide Etchants For The Home Semiconductor Fab

Building circuits on a silicon chip is a bit like a game of Tetris — you have to lay down layer after layer of different materials while lining up holes in the existing layers with blocks of the correct shape on new layers. Of course, Tetris generally doesn’t require you to use insanely high temperatures and spectacularly toxic chemicals to play. Or maybe it does; we haven’t played the game in a while, so they might have nerfed things.

Luckily, [ProjectsInFlight] doesn’t treat his efforts to build semiconductors at home like a game — in fact, the first half of his video on etching oxide layers on silicon chips is devoted to the dangers of hydrofluoric acid. As it turns out, despite the fact that HF can dissolve your skin, sear your lungs, and stop your heart, as long as you use a dilute solution of the stuff and take proper precautions, you should be pretty safe around it. This makes sense, since HF is present in small amounts in all manner of consumer products, many of which are methodically tested in search of a practical way to remove oxides from silicon, which [ProjectsInFlight] has spent so much effort recently to learn how to deposit. But such is the ironic lot of a chip maker.

Three products were tested — rust remover, glass etching cream, and a dental porcelain etching gel — against a 300 nm silicon dioxide layer. Etch speed varied widely, from rust remover’s 10 nm/min to glass etching cream’s blazing 240 nm/min — we wonder if that could be moderated by thinning the cream out with a bit of water. Each solution had pros and cons; the liquid rust remover was cheap easy to handle and clean up, while the dental etching gel was extremely easy to deposit but pretty expensive.

The good news was that everything worked, and each performed differently enough that [ProjectsInFlight] now has a range of tools to choose from. We’re looking forward to seeing what’s next — looks like it’ll be masking techniques.

Continue reading “Testing Oxide Etchants For The Home Semiconductor Fab”

Keebin’ With Kristina Hack Chat

Join us on Wednesday, September 27 at noon Pacific for the Keebin’ with Kristina Hack Chat with our own Kristina Panos!

When you think about it, wiggling your fingers over a bunch of magic chiclets is a pretty strange gateway to the written word. And yet, here we sit a hundred-odd years after someone first decided that the same basic interface used to run pianos and harpsichords for centuries would be a fantastic model for mechanizing the whole writing thing. Just because it makes perfect sense thanks to the outsized portion of our brains dedicated to the motor and sensory functions of our wonderfully complex and versatile hands doesn’t mean it’s not weird.

join-hack-chatStill and all, it seems like there could be some room for improvement in the basic design of keyboards. We could probably do with something that makes typing easier, results in less repetitive strain, or is just more fun to do. Pushing back on the traditional and boring designs of the past is where we find the strange breed of keyboard builders and modders that our very own Kristina Panos counts herself part of. You know here from her popular “Keebin’ with Kristina” series, and now we’ve coaxed her into checking into the Hack Chat to talk to all the rest of us keyboard-minded individuals. If you’ve ever thought that there has to be a better way to enter text, or even just something a little bit different, you’ll want to come along and join the conversation.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, September 27 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

DIY Repair Brings An X-Ray Microscope Back Into Focus

Aside from idle curiosity, very few of us need to see inside chips and components to diagnose a circuit. But reverse engineering is another story; being able to see what lies beneath the inscrutable epoxy blobs that protect the silicon within is a vital capability, one that might justify the expense involved in procuring an X-ray imager.  But what’s to be done when such an exotic and expensive — not to mention potentially deadly — machine breaks down? Obviously, you fix it yourself!

To be fair, [Shahriar]’s Faxitron MX-20 digital X-ray microscope was only a little wonky. It still generally worked, but just took a while to snap into the kind of sharp focus that he needs to really delve into the guts of a chip. This one problem was more than enough to justify tearing into the machine, but not without first reviewing the essentials of X-ray production — a subject that we’ve given a detailed look, too — to better understand the potential hazards of a DIY repair.

With that out of the way and with the machine completely powered down, [Shahriar] got down to the repair. The engineering of the instrument is pretty impressive, as it should be for something dealing with high voltage, heavy thermal loads, and ionizing radiation. The power supply board was an obvious place to start, since electrostatically focusing an X-ray beam depends on controlling the high voltage on the cathode cup. After confirming the high-voltage module was still working, [Shahriar] homed in on a potential culprit — a DIP reed relay.

Replacing that did the trick, enough so that he was able to image the bad component with the X-ray imager. The images are amazing; you can clearly see the dual magnetic reed switches, and the focus is so sharp you can make out the wire of the coil. There are a couple of other X-ray treats, so make sure you check them out in the video below.

Continue reading “DIY Repair Brings An X-Ray Microscope Back Into Focus”

RP2040 Emulator Brings The Voice Of The 80s Back To Life

You may not have heard, but there’s a chip shortage out there. And it’s not just the fancy new chips that are in short supply; the chips that were fancy and new back when you could still buy them from Radio Shack are getting hard to come by, too. For different reasons, of course, but it does pose a problem that requires a little hacking to fix.

The chip in question here is the General Instrument SP0256, a 1980s-era speech synthesizer chip that [Andrew Menadue] relies on. The LSI chip stored 59 unique allophones, or basic sounds the vocal tract is capable of, and synthesized speech by rapidly concatenating these sounds. The chip and its descendants made regular appearances in computers and games throughout the 80s, so chances are good you’ve heard it. If not, think WarGames (yes, we know that wasn’t actually a computerized voice) or [Stephen Hawking] and you’ll be pretty close.

[Andrew]’s need for such a chip stems from his attempts to give voice to his collection of Psion Organisers, another 80s relic that was one of the first pocket computers. Some time ago he built a speech board for the Psion based on the SP0256-AL2, but had to resort to building an emulator for the chip since none were to be had. The emulator uses an RP2040 and lives on a PCB that has the same footprint as the original chip, so it can just plug right in. He dug up WAV files of the allophones and translated those to sequences of bytes, allowing the RP2040 to output the correct sounds as they’re called for. Speaker problems notwithstanding, it sounds pretty good in the video below.

We’ve featured a fair number of SP0256 projects before, on everything from Amstrad to Z80. We’ve also shown off a few of [Andrew]’s builds before, including this exploration of the voltage tolerance of the RP2040.

Continue reading “RP2040 Emulator Brings The Voice Of The 80s Back To Life”

Altoids Tin Spy Radio Goes Solid State

[Helge Fykse (LA6NCA)] has a type, as they say. At least as far as radios are concerned, he seems to prefer elegant designs that keep the BOM to the minimum needed to get the job done. And Altoids tins — he really seems to like putting radios in Altoids tins.

This QRP transceiver for the 60-meter amateur radio band is a perfect example of that ethos. For the unfamiliar, QRP is Morse code shorthand for decreased power, and is generally used when hams are purposely building and operating radios that radiate very little power, typically below a watt. For this transceiver, [Helge] chose to use modern components, a marked but interesting departure from his recent tube-powered spy radios. The design is centered on a custom oscillator board he designed using an Arduino Pro Mini and an Si5351 oscillator chip. Other components include an ADE-1ASK frequency mixer, an antenna tuner module that can be swapped out for operating on different bands, a receiver that’s little more than a couple of op-amps, and a Darlington pair for an RF power amplifier. Everything fits neatly on a piece of copper-clad board inside the tin box.

As is his tradition, [Helge] was on the air in the field with this radio almost before the solder had time to cool. His first contact was a 240-km shot to a friend, who reported a fine signal from this little gem. And that’s with just powering it off a 9-volt battery when it’s designed to the typical 12-volt supplies hams favor; he estimates this resulted in a signal of about 200 mW. Not too shabby.

Honestly, we’d love to learn more about that oscillator board [Helge] used, and maybe get a schematic for it. We found a little bit about it on his web page, but not the juicy details. If you’re out there, [Helge], please share the wealth.

Continue reading “Altoids Tin Spy Radio Goes Solid State”

Books You Should Read: David Macaulay’s Architecture Series

For a lot of us, there’s a bright line separating the books we enjoyed as children from the “real” books of our more mature years. We all eventually age out of the thin, brightly illustrated picture books we enjoyed in our youth, replacing them with thicker, wordier volumes with fewer and fewer illustrations, until they become so dense with information that footnotes and appendices are needed to convey all the information, and a well-written index is a vital necessity to make use of any of it.

Such books seem like a lot less fun than kids’ books, and they probably are, but most of us adjust to the change and accept the fact that the children’s section of the library doesn’t hold much that’ll interest us anymore. But not all the books that get a “JUV” label on their spines are created equal. Some are far more than picture books, even if the pictures are the main attraction. The books of British-born American author David Macaulay come to mind, particularly the books comprising his Architecture Series.

Macaulay’s books were enormously influential in developing my engineering sensibilities, and are still a pleasure to thumb through these many years later. I still learn something about the history of construction and engineering when I pull one of these books off the shelf, which makes them Books You Should Read.

Continue reading “Books You Should Read: David Macaulay’s Architecture Series”

Radio Apocalypse: The BBC Radio Program That Could(n’t) Have Started WWIII

Here’s a question for you: if you’re the commander of a submarine full of nuclear missiles, how can you be sure what not receiving a launch order really means? If could — and probably does — mean that everything is hunky dory on land, and there’s no need to pull the trigger. Or, could radio silence mean that the party already kicked off, and there’s nobody left to give the order to retaliate? What do you do then?

One popular rumor — or “rumour,” given the context — in the UK holds that BBC Radio 4, or the lack thereof, is sort of a “deadman’s switch” for the Royal Navy’s ballistic missile subs. [Lewis (M3HHY)], aka Ringway Manchester on YouTube, addresses this in the video below, and spoiler alert: it’s probably not true.

Continue reading “Radio Apocalypse: The BBC Radio Program That Could(n’t) Have Started WWIII”