Author: Dan Maloney

3367 Articles

Start Your Semiconductor Fab With This DIY Tube Furnace

August 22, 2023 by 4 Comments

Most of us are content to get our semiconductors from the usual sources, happily abstracting away the complexity locked within those little epoxy blobs. But eventually, you might get the itch to roll your own semiconductors, in which case you’ll need to start gearing up. And one of the first tools you’ll need is likely to be something like this DIY tube furnace.

For the uninitiated, [ProjectsInFlight] helpfully explains in the video below just what a tube furnace is and why you’d need one to start working with semiconductors. Perhaps unsurprisingly, a tube furnace is just a tube that gets really, really hot — like 1,200° C. In addition to the extreme heat, commercial furnaces are often set up to seal off the ends of the tube to create specific conditions within, such as an inert gas atmosphere or even a vacuum. The combination of heat and atmospheric control allows the budding fabricator to transform silicon wafers using chemical and physical processes.

[ProjectsInFlight]’s tube furnace started with a length of heat-resistant quartz glass tubing and a small tub of sodium silicate refractory cement, from the plumbing section of any home store. The tube was given a thin coat of cement and dried in a low oven before wrapping it with nichrome wire. The wrapped tube got another, thicker layer of silicate cement and an insulating wrap of alumina ceramic wool before applying power to cure everything at 1,000° C. The cured tube then went into a custom-built sheet steel enclosure with plenty of extra insulation, along with an Arduino and a solid-state relay to control the furnace. The video below concludes with testing the furnace by growing a silicon dioxide coating on a scrap of silicon wafer. This was helped along by the injection of a few whisps of water vapor while ramping the furnace temperature up, and the results are easily visible.

[ProjectsInFlight] still needs to add seals to the tube to control the atmosphere in there, an upgrade we’ll be on the lookout for. It’s already a great start, although it might take a while to catch up to our friend [Sam Zeloof].

Continue reading “Start Your Semiconductor Fab With This DIY Tube Furnace” →

Mass Production 3D Printing Hack Chat

August 21, 2023 by 13 Comments

Join us on Wednesday, August 23 at noon Pacific for the Mass Production 3D Printing Hack Chat with Gabe Bentz!

We’ll take a wild guess and say that right now, within arm’s length of wherever you’re reading this, there’s something that was produced by injection molding. Look around; it’s there someplace, and whatever it is, thousands or perhaps millions of other identical artifacts were produced along with it, all by squeezing hot plastic into intricately machined metal tools.

It’s not much of an overstatement to say that, for good or for ill, the world is made from injection-molded plastic. But not every product can support the often considerable up-front costs associated with injection molding. The tooling needed is often remarkably complicated and correspondingly expensive, and running the machines that actually do the molding is expensive and highly specialized. Unless you’re committed to making a lot of parts, injection molding might just be out of your league.

join-hack-chatBut does that mean that medium-sized runs of parts are out of luck? Not at all! Gabe Bentz, founder and CEO of Slant 3D, is passionate about filling the manufacturing void where injection molding is prohibitive, either by virtue of start-up costs or because the part design is just not possible to manufacture. His massive print farms are busy day in and day out cranking out parts for customers that otherwise couldn’t be made. So if you’ve ever wondered what it takes to run a print farm, and what kinds of design considerations make a part a candidate for mass production by 3D printing, drop by the chat and we’ll see what he has to tell us.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, August 23 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

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Hackaday Links: August 20, 2023

August 20, 2023 by 14 Comments

In some ways, we’ve become a little jaded when it comes to news from Mars, which almost always has to do with the Ingenuity helicopter completing yet another successful flight. And so it was with the report of flight number 54 — almost. It turns out that the previous flight, which was conducted on July 22, suffered a glitch that cut the flight short by forcing an immediate landing. We had either completely missed that in the news, or NASA wasn’t forthcoming with the news, perhaps until they knew more. But the details of the error are interesting and appear related to a glitch that happened 46 flights before, way back in May of 2021, that involves dropped frames from the video coming from the helicopter’s down-facing navigational camera. When this first cropped up back on flight six, it was only a couple of missed frames that nearly crashed the craft, thanks to confusion between the video stream and the inertial data. Flight engineers updated the aircraft’s software to allow for a little more flexibility with dropped frames, which worked perfectly up until the aborted flight 53.

Continue reading “Hackaday Links: August 20, 2023” →

New Take On The Camera Obscura Brings Paris Indoors

August 19, 2023 by 13 Comments

We haven’t checked, but we’ll go out on a limb here and say this is the first project we’ve featured with a BOM that includes “an apartment in Paris with a breathtaking view of the Eiffel Tower.” We suppose there are other places in the world where a giant camera obscura like this would work too, but you’ve got to admit that the view is pretty spectacular.

Of course, a camera obscura is really just a dark room — that’s literally what it means in Latin — with a small aperture to admit light from the outside world. This projects an inverted image on the opposite wall, which must have looked absolutely magical to pre-technical people and honestly is still pretty stunning today. Either way, it’s a low-tech way of seeing the world in a different light. [Mathieu Stern] decided his camera obscura would turn the traditional design on its head. Literally — he wanted an upright image. Luckily, he found a supplier that makes special optics for camera obscura that do just that. It looks like the optic uses a Dove prism to invert the image, or in this case to turn it back into an upright image.

The real hack here was finding the perfect place with just the right view of the Eiffel Tower — not at all an easy task in a medieval city where streets go where they will and buildings tend to block the sightlines. [Mathieu] eventually managed to find just the right place. With a little aluminum foil to make the rented room really obscura and some strategically positioned sheets to improve the projection surface, he was able to project some beautiful images of the landmark and surrounding cityscape in a panorama on the apartment walls. The video below has some stills and time-lapse sequences that are pretty breathtaking.

We’ve seen other camera obscura before, including this mobile version which may have made things easier for [Mathieu], at the price of giving up a lot of the charm.

Continue reading “New Take On The Camera Obscura Brings Paris Indoors” →

Hackaday Prize 2023: Over-the-Top Programmable Resistor Looks The Part And Performs

August 18, 2023 by 18 Comments

Every once in a while we get wind of a project that we’re reluctant to write up for the simple reason that it looks too good to be true. Not that projects need to be messy to be authentic, mind you, but there are some that are just so finished and professional looking that it gives us a bit of pause. [Sebastian]’s programmable precision resistor is a shining example of such a project

While [Sebastian] describes this as “a glorified decade resistance box,” and technically that’s exactly right — at its heart it’s just a bunch of precision resistors being switched into networks to achieve a specific overall resistance — there’s a lot more going on here than just that. The project write-up, which has been rolling out slowly over the last month or so, has a lot of detail on different topologies that could have been used — [Sebastian] settled on a switched series network that only requires six relays per decade while also minimizing the contribution of relay contact resistance to the network. Speaking of which, there’s a detailed discussion on that subject, plus temperature compensation, power ratings, and how the various decades are linked together.

For as much that’s interesting about what’s under the hood, we’d be remiss to not spend a little time praising the exterior of this instrument. [Sebastian] appears to have spared no expense to make this look like a commercial product, from the rack-mount enclosure to the HP-esque front panel. The UI is all discrete pushbuttons and knobs with a long string of 16-segment LEDs — no fancy touch-screens here. The panel layout isn’t overly busy, and looks like it would be easy to use with some practice. We’d love to hear how the front and rear panel overlays were designed, too; maybe in a future project update.

This honestly looks like an instrument that you’d pay a princely sum to Keithley or H-P to own, at least back in the late 1990s or so. Kudos to [Sebastian] for the attention to detail here.

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Litter Box Sensor Lets You Know Exactly What The Cat’s Been Up To

August 17, 2023 by 16 Comments

In our experience, there’s rarely any question when the cat uses the litter box. At all. In the entire house. For hours. And while it may be instantly obvious to the most casual observer that it’s time to clean the thing out, that doesn’t mean there’s no value in quantifying your feline friend’s noxious vapors. For science.

Now of course, [Owen Ashurst] could have opted for one of those fancy automated litter boxes, the kind that detects when a cat has made a deposit and uses various methods to sweep it away and prepare the box for the next use, with varying degrees of success. These machines seem like great ideas, and generally work pretty well out of the box, but — well, let’s just say that a value-engineered system can only last so long under extreme conditions. So a plain old-fashioned litterbox suffices for [Owen], except with a few special modifications. A NodeMCU lives inside the modesty cover of the box, along with a PIR sensor to detect the cat’s presence, as well as an MQ135 air quality sensor to monitor for gasses. It seems an appropriate choice, since the sensor responds to ammonia and sulfides — both likely to be present after a deposit. Continue reading “Litter Box Sensor Lets You Know Exactly What The Cat’s Been Up To” →

2023 Cyberdeck Contest: Cyberdeck Red Is Ready For Action

August 17, 2023 by 8 Comments

What exactly constitutes a cyberdeck is up for debate, but for us, one thing is clear: A cyberdeck needs to look like it’s ready to go to battle. When the machines finally rise up and try to wipe us all out, someone toting around a machine like Cyberdeck Red is probably going to be a sight for sore eyes; clearly, such a person would be equipped to help us fight back the robotic scourge.

If this cyberdeck looks familiar, it’s for a good reason — it’s [Gabriel]’s second stab at this build. We thought the original was pretty keen, enough so that it won second prize in the 2022 contest. But like many cyberdeck builders, good enough isn’t good enough, and so rather than rest on his laurels, he set about improving a few things. The most visible of the changes are the spiffy new case, which is far less utilitarian than version one, and the new custom-made split keyboard. Things are a little different under the hood too; gone is the Raspberry Pi 4, which was replaced by Latte Panda 3 Delta running Windows. And like the original, version two is absolutely stuffed with sensors and diagnostic gear — a Hack RF SDR for radio work, plus an Analog Discovery 2 which provides everything from an oscilloscope and signal generator to a spectrum analyzer and an impedance tester.

But possibly the most useful feature of Cyberdeck Red is the onboard HDMI projector. The palm-sized, short-throw projector would be perfect for an impromptu combat briefing in an improvised command post, or just watching Netflix. If the machines will allow it, of course.

The 2023 Cyberdeck Contest wraps up August 15, so it looks like [Gabriel] just squeaked this one in on time. We wish him and all the other entrants the best of luck!