NASA Taps Lockheed To Bring Back A Piece Of Mars

February 14, 2022 by Tom Nardi 36 Comments

Since NASA’s Mariner spacecraft made the first up-close observations of Mars in 1964, humanity has lobbed a long line of orbiters, landers, and rovers towards the Red Planet. Of course, it hasn’t all been smooth sailing. History, to say nothing of the planet’s surface, is littered with Martian missions that didn’t quite make the grade. But we’ve steadily been getting better, and have even started to push the envelope of what’s possible with interplanetary robotics through ambitious craft like the Ingenuity helicopter.

Yet, after nearly 60 years of studying our frigid neighbor, all we have to show for our work boils down to so many 1s and 0s. That’s not to say the data we’ve collected, both from orbit and on the surface, hasn’t been extremely valuable. But scientists on Earth could do more with a single Martian rock than any robotic rover could ever hope to accomplish. Even still, not so much as a grain of sand has ever been returned from the planet’s dusty surface.

But if everything goes according to plan, that’s about to change. Within the next decade, NASA and the European Space Agency (ESA) hope to bring the first samples of Martian rocks, soil, and atmospheric gases back to Earth using a series of robotic vehicles. While it’s still unclear when terrestrial scientists should expect delivery of this interplanetary bounty, the first stage of the program is already well underway. The Perseverance rover has started collecting samples and storing them in special tubes for their eventual trip back to Earth. By 2028, another rover will be deployed to collect these samples and load them into a miniature rocket for their trip to space.

Launching the Mars Ascent Vehicle (MAV).

Just last week NASA decided to award the nearly $200 million contract to build that rocket, known officially as the Mars Ascent Vehicle (MAV), to aerospace giant Lockheed Martin. The MAV will not only make history as the first rocket to lift off from a celestial body other than the Earth, but it’s arguably the most critical component of the sample return mission; as any failure during launch will mean the irrevocable loss of all the samples painstakingly recovered by Perseverance over the previous seven years.

To say this mission constitutes a considerable technical challenge would be an understatement. Not only has humanity never flown a rocket on another planet, but we’ve never even attempted it. No matter what the outcome, once the MAV points its nose to the sky and lights its engines, history is going to be made. But while it will be the first vehicle to make the attempt, engineers and scientists have been floating plans for a potential Martian sample return mission for decades. Continue reading “NASA Taps Lockheed To Bring Back A Piece Of Mars” →

Pick And Place Hack Chat Reveals Assembly Secrets

February 11, 2022 by Tom Nardi 9 Comments

These days we’ve got powerful free tools to do CAD and circuit design, cheap desktop 3D printers that can knock out bespoke enclosures, and convenient services that will spin up a stack of your PCBs and send them hurtling towards your front door for far less than anyone could have imagined. In short, if you want to build your own professional-looking gadgets, the only limit is your time and ambition. Well, assuming you only want to build a few of them, anyway.

Once you start adding some zeros to the number of units you’re looking to produce, hand assembling PCBs quickly becomes a non-starter. Enter the pick and place machine. This wonder of modern technology can drop all those microscopic components on your board in a fraction of the time it would take a human, and never needs to take a bathroom break. This week Chris Denney stopped by the Hack Chat to talk about these incredible machines and all the minutiae of turning your circuit board design into a finished product.

Chris is the Chief Technology Officer (CTO) of Worthington Assembly, a quick turn electronics manufacturer in South Deerfield, Massachusetts that has been building and shipping custom circuit boards since 1974. He knows a thing or two about PCB production, and looking to help junior and mid-level engineers create easier to manufacture designs, he started the “Pick, Place, Podcast” when COVID hit and in-person tours of the facility were no longer possible. Now he says he can tell when a board comes from a regular listener by how many of his tips make it into the design.

So what should you be doing to make sure your board assembly goes as smoothly as possible? Chris says a lot of it is pretty common sense stuff, like including clear polarity indicators, having a legible silkscreen, and the use of fiducial markers. But some of the tips might come as something of a surprise, such as his advice to stick with the classic green solder mask. While modern board houses might let you select from a rainbow of colors, the fact is that green is what most equipment has been historically designed to work with.

That black PCB might look slick, but can confuse older pick and place machines or conveyors which were designed with the reflectivity of the classic green PCB in mind. It also makes automated optical inspection (AOI) much more difficult, especially with smaller component packages. That said, other colors such as white and red are less of a problem and often just require some fine tuning of the equipment.

He also pulled back the curtain a bit on how the contract manufacturing (CM) world works. While many might have the impression that the PCB game has moved overseas, Chris says orders of less than 10,000 units are still largely handheld by domestic CMs to minimize turnaround time. He also notes that many assembly houses are supported almost entirely by a few key accounts, so while they may be juggling 50 customers, there’s usually just two or three “big fish” that provide 80% of their business. With such a tight-knit group, he cautions CMs can be a bit selective; so if a customer is difficult to work with they can easily find themselves on the short end of the stick.

While the Hack Chat is officially only scheduled for an hour, Chris hung out for closer to three, chatting with community members about everything and anything to do with electronic design and production. His knowledge and passion for the subject was readily apparent, and we’re glad he was able to make time in his schedule to join us.

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 155: Dual Integrating Spheres, More Magnetic Switches, PlottyBot, Red Hair In Your Wafers

February 11, 2022 by Tom Nardi 2 Comments

This week Hackaday Editor-in-Chief Elliot Williams and Managing Editor Tom Nardi take a close look at two pairs of projects that demonstrate the wildly different approaches that hackers can take while still arriving at the same conclusion. We’ll also examine the brilliant mechanism that the James Webb Space Telescope uses to adjust its mirrors, and marvel over a particularly well-developed bot that can do your handwriting for you. The finer points of living off home-grown algae will be discussed, and by the end of the show, you’ll learn the one weird trick to stopping chip fabs in their tracks.

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!

Direct Download (~70 MB)

Continue reading “Hackaday Podcast 155: Dual Integrating Spheres, More Magnetic Switches, PlottyBot, Red Hair In Your Wafers” →

3D Printed Maglev Switches Are So Hot Right Now

February 8, 2022 by Tom Nardi 31 Comments

It doesn’t happen all the time, but over the years we’ve noticed that once we feature a project, a number of very similar builds often find themselves in our tip line before too long. Of course, these aren’t copycats; not enough time has passed for some competitive maker to spin up their own version. No, most of the time it’s somebody else who was working on a very similar project in isolation, and who now for the first time realizes they aren’t alone.

Thanks to this phenomenon we’re happy to report that yet another 3D printable magnetic levitation switch has come to light. Developed by [famichu], this take on the concept is markedly different from what we’ve seen previously, which in a way makes the whole thing even more impressive. It’s one thing for multiple hackers to develop similar projects independently of each other, as the end goal often dictates the nature of the design itself. But here we’re seeing a project that took the same core concepts and ran in a different direction. Continue reading “3D Printed Maglev Switches Are So Hot Right Now” →

Swapped Dash Module Gives Ford Maverick An Upgrade

February 7, 2022 by Tom Nardi 17 Comments

Ford is looking to make their new Maverick compact truck stand out, and so far, it seems to be working. Not only is it exceptionally cheap for a brand-new hybrid, truck or otherwise, but Ford actively encourages owners to modify their new ride. From standardized mounting points throughout the cabin intended for 3D printed upgrades, to an auxiliary 12 VDC line run to the bed specifically for powering user supplied hardware.

But we doubt even the most imaginative of Blue Oval engineers could have predicted that somebody would rip out the whole dash module and replace it with one from a higher-end Ford this early in the game. While many people can’t even find one of these trucks on the lot, [Tyvemattis] on the Maverick Truck Club forum has detailed his efforts to replace the relatively uninspired stock dash module of his truck with an all-digital version pulled from a 2020 Ford Escape Titanium.

Ford’s rendering of the original Maverick dash module.

Now we say “effort”, but as it turns out, the swap went off nearly without a hitch. The new digital module not only appears to be the identical size and shape as the original, but they both use the same connectors. Presumably this is because both vehicles are based on Ford’s scalable C2 platform, and likely means more components from this family of vehicles such as the Lincoln Corsair or new Bronco could be installed into the Maverick.

So what’s the downside? According to [Tyvemattis], the computer is throwing error messages as the Maverick doesn’t have a lot of the hardware that the dash is trying to communicate with. He also can’t change the vehicle’s driving mode, and the cruise control can only be enabled when the truck is stopped. But probably the most annoying issue is that the fuel gauge is off by 50%, so when the tank is full, it shows you’ve only got half a tank. At least one other user on the forum believes this could be alleviated by modifying the fuel sensor wiring, so it will be interesting to see how difficult a fix it ends up being.

We first ran across the DIY-friendly Maverick back in October of last year, and we’re encouraged to already see owners answering Ford’s challenge by tinkering with the vehicle. Here’s hoping this is the start of a new chapter in the long and storied history of car hacking.

Thanks to [Matt] for the tip.

3D Printed Radiation Shields Get Put To The Test

February 4, 2022 by Tom Nardi 19 Comments

Don’t get too excited, a 3D printed radiation shield won’t keep you from getting irradiated during WWIII. But until the Doomsday Clock starts clanging its midnight bell, you can use one to improve the accuracy of your homebrew weather monitoring station by keeping the sun from heating up your temperature sensor. But how much does it help, and what material should you load up in your extruder to make one? Those questions, and more, are the topic of a fascinating whitepaper included in the upcoming volume of HardwareX.

Design and Implementation of 3-D Printed Radiation Shields for Environmental Sensors not only tests how effective these low-cost shields are when compared to an uncovered sensor, but addresses specific concerns in regards to leaving 3D printed parts out in the elements. Readers who’ve squirted out a few rolls worth of the stuff will know that common polylactic acid (PLA) filament, while easy to work with and affordable, isn’t known for its resilience. In fact, one of the advertised properties of the renewable plastic is that it’s biodegradable (theoretically, at least), so leaving it outside for any length of time sounds like it’s bound to go poorly.

PLA’s mechanical strength dropped rapidly.

To make a long story short, it does. While the team demonstrated that the PLA printed radiation shield absolutely helped preserve the accuracy of the temperature and humidity sensors mounted inside of it, the structure itself began to deform rapidly from UV exposure. Further tests determined that the mechanical strength of the PLA showed a notable reduction in as little as 30 days, and a sharp decline after 90 days.

Luckily, there was more than one plastic horse in the race. In addition to the PLA printed shield, the team also tested a version printed in acrylonitrile styrene acrylate (ASA) which fared far better. There was no visible deformation of the shield, and after 90 days, the reduction in mechanical strength was negligible. It even performed a bit better when it came to shielding the temperature sensor, which the team believes may be due to the material’s optical transmission properties.

So there you have it: a 3D printed radiation shield will absolutely improve the accuracy of your weather sensors, but if you want it to last outside, PLA just isn’t going to cut it. On the other hand, you could also save yourself a whole lot of time by just using a stack of plant saucers. Whatever works.

Thanks to [tahnok] for the tip.

Hackaday Podcast 154: A Good Enough CNC, Stepper Motors Unrolled, Smart Two-Wire LEDs, A Volcano Heard Around The World

February 4, 2022 by Tom Nardi 1 Comment

Join Hackaday Editor-in-Chief Elliot Williams and Staff Writer Dan Maloney for this week’s podcast as we talk about Elliot’s “defection” to another podcast, the pros and cons of CNC builds, and making Nixie clocks better with more clicking. We’ll explore how citizen scientists are keeping a finger on the pulse of planet Earth, watch a 2D stepper go through its paces, and figure out how a minimalist addressable LED strip works. From solving a Rubik’s cube to answering the age-old question, “Does a watched pot boil?” — spoiler alert: if it’s well designed, yes — this episode has something for everyone.

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!

Direct Download (Less than 60 MB)