Hackaday Podcast Episode 348: 50 Grams Of PLA Hold A Ton, Phreaknic Badge Is Off The Shelf, And Hackers Need Repair Manuals

December 5, 2025 by Tom Nardi No comments

Join Hackaday Editors Elliot Williams and Tom Nardi as they go over their picks for the best stories and hacks from the previous week. Things start off with a warning about the long-term viability of SSD backups, after which the discussion moves onto the limits of 3D printed PLA, the return of the Pebble smart watch, some unconventional aircraft, and an online KiCad schematic repository that has plenty of potential. You’ll also hear about a remarkable conference badge made from e-waste electronic shelf labels, filling 3D prints with foam, and a tiny TV powered by the ESP32. The episode wraps up with our wish for hacker-friendly repair manuals, and an interesting tale of underwater engineering from D-Day.

Check out the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

As always, this episode is available in DRM-free MP3.

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Shelf Life Extended: Hacking E-Waste Tags Into Conference Badges

December 3, 2025 by Matt Varian 10 Comments

Ever wonder what happens to those digital price tags you see in stores once they run out of juice? In what is a prime example of e-waste, many of those digital price tags are made with non-replaceable batteries, so once their life is over they are discarded. Seeing an opportunity to breathe new life into these displays, [Tylercrumpton] went about converting them to be the official badge of the Phreaknic 26 conference.

Looking for a solution for a cheap display for the upcoming conference badge, [Tylercrumpton] recalled seeing the work [Aaron Christophel] did with reusing electronic shelf labels. Looking on eBay, he picked up a lot of 100 ZBD 55c-RB labels for just $0.70 a piece. When they arrived, he got to work liberating the displays from their plastic cases. The long-dead batteries in the devices ended up being easily removed, leaving behind just the display and the PCB that drives it.

Another hacker assisting with the badge project, [Mog], noticed that the spacing of the programming pads on the PCB was very close to the spacing of a DB9/DE9 cable. This gave way to a very clever hack for programming the badges: putting pogo pins into a female connector. The other end of the cable was connected to a TI CC Debugger which was used to program the firmware on the displays. But along the way, even this part of the project got an upgrade with moving to an ESP32 for flashing firmware, allowing for firmware updates without a host computer.

The next challenge was how to handle customizing 200 unique badges for the conference. For this, each badge had a unique QR code embedded in the back of the 3D printed case that pointed to an online customization tool. The tool allowed the user to change which of the images was used for the background, as well as input the name they wanted to be displayed on the badge. Once finished, the server would provide a patched firmware image suitable for flashing the badge. The original intent was to have stations where attendees could plug in their badge and it would update itself; however, due to some 11th hour hiccups, that didn’t pan out for this conference. Instead, [Tylercrumpton] ran the update script on his machine, and it gave him a great opportunity to interact with conference attendees as they stopped by to update their badges.

For the Phreaknic 27 badge, the plan is to once again use electronic shelf labels, but this time to utilize some of the advanced features of the tags such as the EEPROM and wireless communications. We’re eager to see what the team comes up with.

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Supercon 2025 Badge Gets Vintage Star Trek Makeover

October 29, 2025 by Tom Nardi 3 Comments

There are still a few days before the doors open on this year’s Hackaday Supercon in Pasadena, but for the most dedicated attendees, the badge hacking has already begun…even if they don’t have a badge yet.

By referencing the design files we’ve published for this year’s Communicator badge, [Thomas Flummer] was able to produce this gorgeous 3D printed case that should be immediately recognizable to fans of the original Star Trek TV series.

Metal hinge pin? Brass inserts? Scotty would be proud.

Although the layout of this year’s badge is about as far from the slim outline of the iconic flip-up Trek communicator as you can get, [Thomas] managed to perfectly capture its overall style. By using the “Fuzzy Skin” setting in the slicer, he was even able to replicate the leather-like texture seen on the original prop.

Between that and the “chrome” trim, the finished product really nails everything Jadzia Dax loved about classic 23rd century designs. It’s not hard to imagine this could be some companion device to the original communicator that we just never got to see on screen.

While there’s no denying that the print quality on the antenna lid is exceptional, we’d really like to see that part replaced with an actual piece of brass mesh at some point. Luckily, [Thomas] has connected it to the body of the communicator with a removable metal hinge pin, so it should be easy enough to swap it out.

Considering the incredible panel of Star Trek artists that have been assembled for the Supercon 2025 keynote, we imagine this won’t be the last bit of Trek-themed hacking that we see this weekend — which is fine by us.

The Supercon 2025 Badge Is Built To Be Customized

October 27, 2025 by Tom Nardi 10 Comments

For anyone who’s joined us for previous years, you’ll know that badge hacking and modification are core to the Hackaday Supercon experience. While you’re of course free to leave the badge completely stock, we encourage attendees to tear it apart, learn how it works, and (hopefully) rebuild it into something unique. There are even prizes for the best hacks.

As such, every decision about the badge’s hardware and software is made with hackability in mind. It’s why we always try to add an expansion port to the badge and, in recent years, have leaned into MicroPython to make it easier for attendees to modify the code.

But one thing that’s been largely missing in previous badges is aesthetic customization. Sure, you could strip out the firmware and write something entirely new, or hang some oddball peripheral off the side of the thing, but ultimately it still looked like the badge we gave you at the door. That’s because, at the end of the day, the badges are just PCBs. Short of designing your own enclosure (which has certainly been done), every badge looks the same. That is, until now.

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Announcing The 2025 Hackaday Superconference Communicator Badge

October 23, 2025 by Elliot Williams 44 Comments

It’s the moment you hard-core hardware nerds have been waiting for: the reveal of the 2025 Hackaday Supercon Communicator Badge. And this year, we’ve outdone ourselves, but that’s thanks to help from stellar collaboration with folks from the community, and help from sponsors. This badge is bigger than the sum of its parts, and we’ve planned for it to be useful for you to hack on in the afterlife. Indeed, as always, you are going to be the final collaborator, so we can’t wait to see what you’ll do with it.

We’re going out – wide out – on a limb and trying to create a dense mesh network of badges talking to each other at Supercon. It’s going to be like a badge-hosted collection of chat rooms, as connected as we can make them without talking over each other.

You look up a topic, say Retro Computing or SAO trading, punch in the channel number on the numpad, and your badge starts listening to everything going on around that topic. But they also listen to everything else, and repeat anything they hear on to their neighbors. Like IRC, but LoRa.

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Decorate Your Neck With The First Z80 Badge

September 28, 2025 by Jenny List 4 Comments

Over the years, we’ve brought you many stories of the creative artwork behind electronic event badges, but today we may have a first for you. [Spencer] thinks nobody before him has made a badge powered by a Z80, and we believe he may be right. He’s the originator of the RC2014 Z80-based retrocomputer, and the badge in question comes from the recent RC2014 Assembly.

Fulfilling the function of something you can write your name on is a PCB shaped like an RC2014 module, with LEDs on all the signal lines. It could almost function as a crude logic analyser for the system, were the clock speed not far too high to see anything. To fix this, [Spencer]’s badge packs a single-board RC2014 Micro with a specially slow clock, and Z80 code to step through all memory addresses, resulting in a fine set of blinkenlights.

Thus was created the first Z80-based event badge, and we’re wondering whether or not it will be the last. If you’re curious what this RC2014 thing is about, we reviewed the RC2014 Micro when it came out.

The WHY 2025 Badge And Its 18650s

August 12, 2025 by Jenny List 38 Comments

The largest European hacker camp this year was in the Netherlands — What Hackers Yearn (WHY) 2025 is the latest in the long-running series of four-yearly events from that country, and 2025 saw a move from the Flevoland site used by SHA2017 and MCH2021, back to just north of Alkmaar in Noord-Holland, where the OHM2013 event took place. WHY has found itself making the news in the Dutch technical media for all the wrong reasons over the last few days, after serious concerns were raised about the fire safety of its badge.

The cell supplied with a WHY 2025 badge, with very clear fire safety warning — This is the cell supplied with the WHY badge, complete with manufacturer’s warning.

The concerns were raised from the RevSpace hackerspace in Leidschendam, and centre around the design of the battery power traces on the PCB between the battery holders and the power supply circuitry. Because the 18650 cells supplied with that badge lack any protection circuitry, bridging the power traces could be a fire risk.

In short: their report names the cell holders as having tags too large for their pads on the PCB, a too-tight gap between positive and negative battery traces, protected only by soldermask, and the inadequacy of the badge’s short circuit protection. In the event that metal shorted these battery tags, or wore through the soldermask, the batteries would be effectively shorted, and traces or components could get dangerously hot.

The WHY organizers have responded with a printed disclaimer leaflet warning against misuse of the cells, and added a last-minute epoxy coating to the boards to offer additional protection. Some people are 3D-printing cases, which should also help reduce the risk of short-circuiting due to foreign metal objects. Using an external powerbank with short-circuit protection instead of the cells would solve the problem as well. Meanwhile a group of hackers collecting aid for Ukraine are accepting the batteries as donations.

It’s understood that sometimes bugs find their way into any project, and in that an event badge is no exception. In this particular case, the original Dutch badge team resigned en masse at the start of the year following a disagreement with the WHY2025 organizers, so this badge has been a particularly hurried production. Either way, we are fortunate that the issue was spotted, and conference organizers took action before any regrettable incidents occurred.