Thinnest Keyboard Uses Cherry DIY Doubleshot Method

May 10, 2022 by 24 Comments

As with any other community, it takes all kinds to make the keyboard world go ’round. Some like them thicc — more backing for the clacking and all — but some like them sleek and prefer the slimmest possible keyboard. For now and the foreseeable future, the go-to method for making whisper-thin keebs is to use Kailh Choc switches, because that’s about all that’s out there.

But chocs aren’t for everyone, and there are plenty of die-hard Cherry fans out there that want it both ways. Being one among them, [Khmel] set about designing the lowest-profile possible keyboard (and caps) that uses standard Cherry-sized keyswitches. Shut up and take your money? Well, okay, but the case and keycap files are all available on Thingiverse, so.

The whole video is great, and at less than 2½ minutes long, it’s definitely worth your time. There are a few little gems of wisdom sprinkled throughout, like printing keycaps standing up on their backsides (like where they would have a little flash dot if they were factory-molded). This gives them a nice texture thanks to the layer lines. But the real reason we’re here today is this DIY method for making doubleshot keycaps with little fuss that [Khmel] just tosses out there toward the end.

Trust us, there’s a piece of glass there.

Traditionally, doubleshot keycaps are made with two layers of plastic — one for the legend, and one for the rest. This produces a quite durable keycap and (used to be the norm), but the expensive process gave way to laser-etched and pad-printed keycap legends in the ’90s. [Khmel] was able to fake the look by printing legends at 0.25 layer height and then fusing each one to its respective keycap by laying a thin piece of glass (think microscope slide) on top and applying a soldering iron for a few seconds. Classy!

Tweezing tiny legends not really your kind of tedium? Here’s a method for DIY waterslide decals instead.

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Data Alignment Across Architectures: The Good, The Bad And The Ugly

May 10, 2022 by 19 Comments

Even though a computer’s memory map looks pretty smooth and very much byte-addressable at first glance, the same memory on a hardware level is a lot more bumpy. An essential term a developer may come across in this context is data alignment, which refers to how the hardware accesses the system’s random access memory (RAM). This and others are properties of the RAM and memory bus implementation of the system, with a variety of implications for software developers.

For a 32-bit memory bus, the optimal access type for some data would be a four bytes, aligned exactly on a four-byte border within memory. What happens when unaligned access is attempted – such as reading said four-byte value aligned halfway into a word – is implementation defined. Some hardware platforms have hardware support for unaligned access, others throw an exception that the operating system (OS) can catch and fallback to an unaligned routine in software. Other platforms will generally throw a bus error (SIGBUS in POSIX) if you attempt unaligned access.

Yet even if unaligned memory access is allowed, what is the true performance impact? Continue reading “Data Alignment Across Architectures: The Good, The Bad And The Ugly” →

Theory, Practice, And Ducted Fans

May 10, 2022 by 9 Comments

About a year ago, [Wyman’s Workshop] needed a fan. But not just a regular-old fan, no sir. A ducted fan. You know, those fancy fan designs where the stationary shroud is so close to the moving fan blades that there’s essentially no gap, and a huge gain in aerodynamic efficiency? At least in theory?

Well, in practice, you can watch how it turned out in this video. (Also embedded below.) If you’re more of a “how-to-build-it” type, you’ll want to check out his build video — there’s lots of gluing 3D prints and woodworking. But we’re just in it for the ducted fan data!

And that’s why we’re writing it up! [Wyman] made a nice thrust-testing rig that the fan can pull on to figure out how much force it put out. And the theory aimed at 652 g of thrust, which was roughly confirmed. And then you get to power: with a 500 watt motor, he ended up producing 47 watts. Spoiler: he’s overloading the motor, even though he used a fairly beefy bench grinder motor.

So he re-did the fan design, from scratch, to better match the motor. And it performed better than the theory said it would. A pleasant surprise, but it meant re-doing the theory, including the full volume of the fan blade, which finally brought theory and practice together. Which then lead him design a whole slew of fan blades and test them out against each other.

He ends the video with a teaser that he’ll show us the results from various inlet profiles and fan cones and such. But the video is a year old, so we’re not holding our breath. Still, if you’re at all interested in fan design, and aren’t afraid of high-school physics, it’s worth your time.

Don’t care about the advantages of ducted fans, but simply want to make your quad look totally awesome?  Have we got the hack for you!

Continue reading “Theory, Practice, And Ducted Fans” →

Large Scale Carbon Capture Without The Technology

May 10, 2022 by 213 Comments

We humans are in something of a pickle, as we’ve put too much carbon dioxide in the atmosphere and caused climate change that might even wipe us out. There may still be people to whom that’s a controversial statement, but knowing something needs to be done about it should be a position for which you don’t necessarily have to be a climate change activist glueing yourself to the gates of a refinery.

It’s obvious that we can reduce our CO2 emissions to tackle the problem, but that’s not the only way that atmospheric CO2 can be reduced. How about removing it from the air? It’s an approach that’s being taken seriously enough for a number of industrial carbon capture solutions to be proposed, and even for a pilot plant to be constructed in Iceland. The most promising idea is that CO2 from power stations can be injected into porous basalt rock where it can react to form calcium carbonate. All of which is very impressive, but is there not a way that this can be achieved without resorting to too much technology? Time for Hackaday to pull out the back-of-envelope calculator, and take a look. Continue reading “Large Scale Carbon Capture Without The Technology” →

3D Print Finishing By Spraying Glazing Putty

May 10, 2022 by 19 Comments

Finishing off 3D prints is a labour-intensive process, and getting a good looking, smooth surface suitable for painting takes a lot of time and plenty of practice. Deeper printing layer lines or minor surface defects can be smoother over with a variety of materials, from putties to resins, but the deeper the defect, the thicker the filler and that takes it toll on the surface details – smoothing those out and making fine details less distinct. [Darkwing dad] has another solution that looks pretty easy to achieve, by mixing acetone with glazing putty it can be airbrushed over the print surface in one go. After a little experimentation with the ratio of putty to acetone, a wide open nozzle and a low pressure, it was found that a nice even spray could be achieved. Importantly it dries in just a few minutes, enabling multiple coats to be applied in a short space of time.

Once sufficient thickness has been applied, the coating can easily sanded to get a smooth result with the worst of the gaps filled, and the layer lines nicely hidden. The final part of the filling process is more typical, with a few coats of filler primer applied straight from a rattle can, followed by a light sand and you’re good for painting.

We’ve covered smoothing 3D prints practically as long as we’ve been covering 3D printing itself, and there are multiple ways to do this, depending on the filament material, your budget and you tolerance for noxious fumes. Here’s a guide for smoothing using UV curable resins, using a special smoothable filament with IPA, and finally if this is just too fancy, smelly or expensive, just whip out the old butane torch and smooth those prints with good old fashioned fire.

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Becky Stern, David Cranor, And A CT Scanner Vs The Oura Ring

May 10, 2022 by 7 Comments

If you wonder how it’s possible to fit a fitness tracker into a ring, well, you’re not alone. [Becky Stern] sent one off to get CT scanned, went at it with a rotary tool, and then she made a video about it with [David Cranor]. (Video embedded below.)

While it’s super cool that you can do a teardown without tearing anything down these days — thanks to the CT scan — most of the analysis is done on a cut-up version of the thing through a normal stereo microscope. Still, the ability to then flip over to a 3D CT scan of the thing is nice.

We absolutely concur with [Becky] and [David] that it’s astounding how much was fit into very little space. Somewhere along the way, [David] muses that the electrical, mechanical, and software design teams must have all worked tightly together on this project to pull it off, and it shows. All along, there’s a nice running dialog on how you know what you’re looking at when tearing at a new device, and it’s nice to look over their shoulders.

Then there’s the bit where [Becky] shows you what a lithium-ion battery pack looks like when you cut it in half. She says it was already mostly discharged, and she didn’t burst into flames. But take it easy out there! (Also, make sure you take your hot xylene out on the patio.)

X-ray machines are of course just the coolest thing when doing a teardown. We’ve seen them used from fixing multimeters to simply looking at servo motors.

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Will MiSTer Fool You Into Learning FPGAs?

May 9, 2022 by 45 Comments

What’s the killer app for FPGAs? For some people, the allure is the ultra-high data throughput for parallelizable tasks, which can enable some pretty gnarly projects. But what if you’re just starting out? How about 1980s style video games?

The MiSTer FPGA project created a bit of FPGA hardware that makes it easy to build essentially any old school video game or computer platform. That’s a massive clean slate. Of course, you can simply download someone else’s Atari ST or Commodore 64 setup and load it up, but if you want to learn FPGAs while recreating old-school video game machines, you’re going to want to get your hands dirty.

[Mister Retro Wolf] started up a video series last winter (trailer embedded below) where he’s embarked on a project to recreate a classic video game machine from the ground up using the MiSTer FPGA platform. In particular, he’s going to recreate the Namco Tank Battalion arcade game, from the schematics, in Verilog.

This is literally building a 6502-based video game machine from scratch (in gateware), so if you’re interested in retrocomputing or FPGAs, you’ll have something to learn here. He’s gotten through the CPU, screen, tilemap graphics, and memory so far, but it’s not done yet. To follow along, get yourself some hardware and you can probably catch up.

We’ve covered the MiSTer FPGA project before, of course, because we think it’s cool. And if a video game arcade machine is going to be your gateway drug into the seedy world of programmable gates, then so be it.

Continue reading “Will MiSTer Fool You Into Learning FPGAs?” →