The Open Source ASICs Hack Chat Redefines Possible

March 18, 2022 by Tom Nardi 4 Comments

There was a time when all that was available to the electronics hobbyist were passive components and vacuum tubes. Then along comes the integrated circuit, and it changed everything. Fast forward a bit, and affordable programmable microcontrollers arrived on the scene. Getting started in electronics became far easier, and the line between hardware and software started to blur. Much more recently, the hobbyist community was introduced to field programmable gate arrays (FPGAs) and the tools necessary to work with them. While not as widely applicable as the IC or MCU, the proliferation of FPGAs among hardware hackers once again opened doors that were previously locked tight.

We’re currently on the edge of another paradigm shift, but it’s no surprise if you haven’t heard of it. After all, the last couple of years have been a bit unusual, so the 2020 announcement that Google was teaming up with SkyWater and Efabless to enable the design and manufacture of open source application-specific integrated circuits (ASICs) flew under the radar for many people. But not Matt Venn, the host of this week’s Hack Chat. For him, it was the opportunity he’d been waiting for.

Matt started like many of us, building electronic kits and building new gadgets out of old discarded hardware. He graduated to microcontrollers, and became particularly interested in FPGAs when the open source toolchains started hitting the scene. Of course by this point, it was much more than just a hobby for him. He was presenting a talk at the 2019 Week of Open Source Hardware in Switzerland when he saw Tim Edwards from Efabless demo a chip that had been made with open source tools. Unfortunately, the costs involved were still far too high for an individual to put their ideas into silicon.

So when Google and Skywater announced they would be footing the bill to have selected open source ASIC designs manufactured a few months later, Matt says he was in a good position to jump in. He has since started running the Zero to ASIC Course which aims to teach you how to produce your own chips using the open source Process Development Kit, and so far 160 people have taken him up on the offer.

As you might expect, many of the questions in the Chat had to do with what kind of designs you can actually produce using the 130 nm process. Especially given the limits on the physical space each creator’s circuit can take up on each multi-project wafer (MPW). Others wanted to know how difficult it would be to port over existing FPGA designs, or how well the process worked with analog applications. With the number of designs Matt has seen go through his course, he could answer many of the questions just by pointing to a particular individual’s ASIC. For instance, he held up the digital-to-analog converter from Harald Pretl and Thomas Parry’s 5 GHz satellite transceiver as prime analog examples.

So let’s say you put the work in to design an ASIC and it gets approved to be produced on a future MPW, what then? Well, first you have to hope everything goes according to plan. Matt explains that the initial run was almost a total write-off due to timing problems in the toolchain, though in the end, he was largely able to recover his own chip. But they’ve done several runs since then, so let’s assume there’s no production problems. What exactly ends up on your doorstep?

If you were expecting a handy DIP8, you might be disappointed. While some DIY friendly packages would be nice, right now the ASICs ship as wafer level chip scale package (WLCSP) with an unforgiving 0.5 mm pitch. If you can believe it, that’s actually an improvement over the first run, which shipped out as a bare die. Of course as Matt pointed out, anyone who’s gotten to the point of designing their own custom ASIC probably won’t be scared off by the prospect of some fine-pitch soldering. Some in the Chat wondered about the difficulty in getting compatible PCBs produced, but Matt said that in his experience OSH Park has been up to the challenge.

Like the Metal 3D Printing Hack Chat before it, this week’s session went over a topic that’s on the absolute cutting edge of what’s possible for hardware hackers and hobbyists. Truth be told, the vast majority of the people reading Hackaday are no more likely to send away for their own custom ASIC as they are to battle x-rays in an attempt to sinter metal with a homebrew electron gun. But that doesn’t make the fact that some folks out there doing it any less important, or inspiring. That said, if you do end up being one of those select few that can boast they’ve designed a custom chip of their own — don’t forget to send one of them our way.

We’re grateful Matt Venn was able, once again, to share his valuable experience in the realm of open source application-specific integrated circuits with us. If you haven’t checked them out already, the Zero to ASIC workshop he ran for Remoticon 2020 and his talk Open Source ASICs – A Year in Perspective from Remoticon 2021 are required viewing if you want to learn more about this fascinating new frontier in hardware hacking.

The Hack Chat is a weekly online chat session hosted by leading experts from all corners of the hardware hacking universe. It’s a great way for hackers connect in a fun and informal way, but if you can’t make it live, these overview posts as well as the transcripts posted to Hackaday.io make sure you don’t miss out.

Hackaday Podcast 160: Pedal Power, OpenSCAD In The Browser, Tasmanian Tigers, And The Coolest Knob

March 18, 2022 by Tom Nardi 1 Comment

Join Hackaday Editor-in-Chief Elliot Williams and Managing Editor Tom Nardi as they tackle all the hacks that were fit to print this last week. Things start off with some troubling news from Shenzhen (spoilers: those parts you ordered are going to be late), and lead into a What’s That Sound challenge that’s sure to split the community right down the center. From there we’ll talk about human powered machines, bringing OpenSCAD to as many devices as humanly possible, and the finer points of installing your own hardware into a Pelican case. There’s a quick detour to muse on laser-powered interstellar probes, a Pi-calculating Arduino, and a surprisingly relevant advertisement from Sony Pictures. Finally, stay tuned to hear the latest developments in de-extinction technology, and a seriously deep dive into the lowly nail.

Or Direct Download, like an old-school boss!

Take a look at the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

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Simple Arduino Build Lets You Keep An Eye On Pi

March 15, 2022 by Tom Nardi 10 Comments

Are you a math aficionado in need of a new desk toy? Then do we have the project for you. With nothing more than an Arduino and a seven-segment LED module, [Cristiano Monteiro] has put together a little gadget that will slowly work its way through the digits of Pi forever…or until you get bored of looking at it and decide to use the parts for something else.

On the hardware side, we really can’t overstate how simple this project is. A common four-digit LED display is connected up to an Arduino Nano, which is then plugged into the computer for power. [Cristiano] is using a breadboard here, but you could just as easily use four female-to-female jumpers to connect the two devices together. We suppose this would be a pretty good project for anyone who’s looking to get some practical experience with PCB design as well.

The real magic is in the software, which [Cristiano] has been kind enough to release under the MIT license. Calculating Pi on such a resource-constrained chip as the ATmega328P is far from ideal, but by porting over a C++ algorithm developed by [Xavier Gourdon] and [Pascal Sebah] for their paper Computation of the n-th Decimal Digit of π with Low Memory he was able to pull it off, albeit slowly.

Now if you’ve got slightly better hardware, say a pair of Xeon processors and 96 GB of RAM, you could calculate Pi out to a few trillion digits for fun, but it wouldn’t look as cool as this little guy blinking away.

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Cheap Ghostbusters Toy Turned Convincing Prop

March 14, 2022 by Tom Nardi 2 Comments

As you might expect, the release of last year’s Ghostbusters: Afterlife has not only lead to renewed interest in the old 1980s toys and tie-in merchandise, but has spawned a whole new generation of blinking plastic gadgets to delight children of all ages. Of course, for folks like us, that means more hardware to hack on.

In a recent post to the official Ghostbusters YouTube channel, professional prop maker [Ben Eadie] shows off some of the tricks of the trade when he takes a $15 USD “PKE Meter” toy from Hasbro and turns it into a screen-quality prop. Even if you’re not looking to get an early start on your Halloween costume, the techniques demonstrated in this video could be easily adapted to other projects. For those whose next ideal home improvement is a fireman’s pole and an ectoplasmic laser-confinement grid, you might want to grab a couple of these toys while they’re still cheap for eventual conversion.

Uncovering the silver makes the piece look worn down.

The biggest takeaway from the video is probably the finishing techniques, as they could be used on any sort of realistic prop build. [Ben] starts by using a cabinet scraper to smooth out the lines on the plastic toy, and any holes are filled with the familiar baking soda and cyanoacrylate glue trick. Once the surfaces have been prepped, all the principle parts are sprayed with an adhesion promoter, followed by a coat of silver, and then the final black color.

This allows him to create a convincing “chipped paint” effect by strategically sanding or scraping through the top coat. Dabbing some toothpaste where you want the device to look worn down before spraying the final coat makes the process even faster, as it will prevent the top coat from sticking to the silver in the first place.

Unfortunately [Ben] doesn’t spend a whole lot of time explaining the electronics side of things, but it doesn’t look like there’s anything too complex going on. All the original gear is stripped, and it gets replaced with a microcontroller which we believe is an Adafruit ItsyBitsy nRF52840 Express. This is connected to two strings of tiny APA102 addressable LEDs which are run down the “wings” (we especially like the 3D printed lenses used to replace the original solid pips), and one that’s used to provide the iconic sine-wave display.

While the last PKE meter build we saw did detect radiation, we have to admit that in terms of looks, this one takes the top spot. Especially when you consider how cheap the thing was. All you need now is a Proton Pack, and you’ll be ready for Halloween.

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The Metal 3D Printing Hack Chat Brings The Heat

March 11, 2022 by Tom Nardi 8 Comments

At this point, it’s safe to say the novelty of desktop 3D printing has worn off. The community has largely come to terms with the limitations of extruded plastics, and while we still vehemently believe that it’s a transformative technology, we’ll admit there aren’t too many applications where a $200 USD printer squirting out PLA is truly the best tool for the job.

But rather than looking at today’s consumer 3D printer market as the end of the line, what if it’s just the beginning? With the problems of slicing, motion control, and extrusion more or less solved when it comes to machines that print in plastic, is it finally time to turn our attention to the unique problems inherent in building affordable metal printers? Agustin Cruz certainly thinks so, which is why he took to the Hack Chat this week to talk about his personal vision for an open source 3D printer that can turn powdered metals into solid objects by way of a carefully controlled electron beam.

To be clear, Agustin isn’t suggesting you toss out your Creality anytime soon. Metal 3D printing will always be a niche within a niche, but for applications where even advanced engineering plastics like PEI and PEEK simply won’t do, he argues the community needs to have a cheap and accessible option. Especially for developing and low income countries where traditional manufacturing may be difficult. The machine he’s been working on wouldn’t be outside the capabilities of an individual to build and operate, but at least for right now the primary target is hospitals, colleges, and small companies.

The Chat was full of technical questions about Agustin’s design, and he wasn’t shy about tackling them. Some wondered why he decided to sinter the metal powder with an electron gun when solid-state lasers are cheap, easily available, and relatively straightforward to work with. But while the laser might seem like the easier solution on the surface, Agustin points out that using a magnetically focused electron beam gives his printer some unique capabilities.

For example, he can easily defocus the beam and pass it over the entire build plate to pre-heat the powder. The steerable beam doesn’t require mirrors either, which not only reduces the weight and complexity of the machine, but in theory should allow for faster print speeds. The beam can be moved in the X/Y dimensions with an accuracy of 0.01 mm, and while the beam diameter is currently a respectable 0.5 mm, Agustin says he’s working on bringing that down to 0.1 mm for high detail work. The temperature at the focal point of the beam is between 1,400 and 1,500 °C, which he notes is not only hot enough to melt the powdered metal, but can also weld stainless steel.

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Hackaday Podcast 159: Zombie Killer Or Rug Maker, 3D Printed Rims, 1950s Drum Machines, And Batteries On Wheels

March 11, 2022 by Tom Nardi No comments

Join Hackaday Editor-in-Chief Elliot Williams and Managing Editor Tom Nardi as they look back on the best hacks and stories of the previous week. There’s plenty in the news to talk about, though between faulty altimeters and the ongoing conflict in Ukraine, it isn’t exactly of the positive variety. But things brighten up quickly as discussion moves on to 3D printed car wheels, a fantastically complex drum machine from 1958, a unique take on the seven-segment flip display, and a meticulously designed (and documented) coffee machine upgrade. Somewhere in there a guy also recreates a rare German anti-air rocket launcher from WWII, but it’s all in the name of history. We’ll also tackle two very different forms of electric propulsion, from the massive wheeled batteries popping up in garages and driveways all over the world to high-efficiency thrusters for deep space missions.

Direct Download (~60 MB)

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The Fliegerfaust Roars Back To Life After 77 Years

March 9, 2022 by Tom Nardi 36 Comments

As their prospects for victory in the Second World War became increasingly grim, the Germans developed a wide array of outlandish “Wonder Weapons” that they hoped would help turn the tide of the war. While these Wunderwaffe obviously weren’t enough to secure victory against the Allies, many of them represented the absolute state-of-the-art in weapons development, and in several cases ended up being important technological milestones. Others faded away into obscurity, sometimes with little more then anecdotal evidence to prove they ever even existed.

One of these forgotten inventions is the Fliegerfaust, a portable multi-barrel rocket rocket launcher designed for use against low-flying attack planes. Although thousands were ordered to defend Berlin in 1945, fewer than 100 were ever produced, and there’s some debate about how many actually survived the war. But that didn’t stop [Jonathan Wild] of Wild Arms Research & Development from building a functional replica of the weapon based on contemporary documentation and blueprints.

Building the launcher was relatively straightforward, as it’s little more than nine tubes bundled together with a handle and a simplistic electric igniter. The trick is in the 20 mm (0.78 inch) rockets themselves, which are spin stabilized by the exhaust gasses exiting the four angled holes on the rear. With no fins or active guidance the path of each rocket is somewhat unpredictable, but this was known to be true of the original as well.

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