One Tool Twists Wires, And Skewers Shish Kebabs

February 11, 2022 by Chris Lott 19 Comments

Twisting stranded wire with your fingers in preparation for tinning and/or soldering is almost a reflex for folks making electronic assemblies. But what if the wires are too close to get your fingers around, or you have the fingers of a sumo wresters? Well [DIYDSP] has a solution for you (see video below the break) that’s easy to make from a shish kebab skewer that’s probably rolling around your kitchen drawer. The reason that [DIYDSP] wanted to twist such closely spaced wires was to solder a length of 0.1 in O.C. stranded ribbon cable directly onto a PCB pin header pattern.

The method is very simple. Drill a long hole in the factory-cut flat end, followed by using a countersink bit to give a conical taper to guide the wires in. [DIYDSP] found that a 1/16 inch (1.6 mm) drill bit was a bit too large to grip the types of wires he was using, and finally settled on a 0.6 mm bit. If you are using larger wires, you should experiment to get the right size, or just build a handful of these of differing diameters since they’re so easy to make — just mark them clearly so you don’t accidentally grill shish kebabs with them on the BBQ.

The resulting tool is not unlike the business end of a hand-held wire-wrap tool, but works different principle and is a fraction of the cost. If you do any amount of interconnect wiring with stranded wires, then you should check out this video and whip up a couple of these to throw in your tool box.

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Tiny TV Celebrates The Forgotten Tech Of CRTs

February 11, 2022 by Dan Maloney 35 Comments

For those of us who grew up before the Internet, the center of pretty much every house was the TV. It was the shrine before which we all worshipped, gathering together at the appointed times to receive the shared wisdom of mass entertainment. In retrospect, it really wasn’t that much. But it’s what we had.

Content aside, one thing all these glowing boxes had in common was that which did the glowing — the cathode ray tube (CRT). Celebrating the marvel of engineering that the CRT represents is the idea behind [Matt Evan]’s tiny desktop TV. The design centers around a 1.5″ CRT that once served as a viewfinder on a 1980s-vintage Sony camcorder. [Matt] salvaged the tube and the two PCB assemblies that drive it, mounting everything in a custom-built acrylic case, the better to show off the bulky but beautiful tube.

The viewfinder originally used a mirror to make the optical path more compact; this forced [Matt] to adapt the circuit to un-reverse the image for direct viewing. Rather than receiving analog signals off the air as we did in the old days — and we liked it that way! — the mini monitor gets its video from a Raspberry Pi, which is set to play clips of TV shows from [Matt]’s youth. Rendered in glorious black and white and nearly needing a magnifying glass to see, it almost recaptures the very earliest days of television broadcasting, when TVs all had screens that looked more like oscilloscope CRTs.

This project is a nice homage to a dying technology, and [Matt] says it has spurred more than one conversation from people you grew up knowing only LCD displays. That’s not to say CRTs are totally dead — if you want to build your own old-school TV, there’s a kit for that.

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)

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A Most Unconventional Lego Walker

February 11, 2022 by Lewin Day 15 Comments

Lego Technic is a wonderful thing, making it easy to toy around with all manner of complicated mechanical assemblies without needing to do any difficult fabrication. [touthomme] recently posted one such creation to Reddit – a walker design that is rather unconventional.

The design dispenses with individually-actuated legs entirely. Instead, the two front legs are joined by an axle which pivots the legs about the body, which is shaped like an oval track. The rear legs are the same. A motorized carriage then travels along the oval track. When the weighted carriage reaches the front of the oval track, it forces the body to tip forwards, pivoting around the front legs and flipping the entire body over, swinging the rear legs forwards to become the front. The cycle then repeats again.

The flipping design, inspired by a toy, is something you wouldn’t expect to see in nature, as few to no animals have evolved mechanisms capable of continual rotation like this. It’s also unlikely to be a particularly efficient way of getting around, and the design would certainly struggle to climb stairs.

Some may claim the method of locomotion is useless, but we don’t like to limit our imaginations in that way. If you can think of a situation in which this walker design would be ideal, let us know in the comments. Alternatively, consider other walking designs for your own builds. Video after the break.

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This Week In Security: Zimbra, Lockbit 2, And Hacking NK

February 11, 2022 by Jonathan Bennett 9 Comments

Unknown attackers have been exploiting a 0-day attack against the Zimbra e-mail suite. Researchers at Volexity first discovered the attack back in December of last year, detected by their monitoring infrastructure. It’s a cross-site scripting (XSS) exploit, such that when opening a malicious link, the JavaScript running on the malicious page can access a logged-in Zimbra instance. The attack campaign uses this exploit to grab emails and attachments and upload them to the attackers. Researchers haven’t been able to positively identify what group is behind the attacks, but a bit of circumstantial evidence points to a Chinese group. That evidence? Time zones. The attacker requests all use the Asia/Hong_Kong time zone, and the timing of all the phishing emails sent lines up nicely with a work-day in that time zone.

Zimbra has responded, confirming the vulnerability and publishing a hotfix for it. The campaign seems to have been targeted specifically against European governments, and various media outlets. If you’re running a Zimbra instance, make sure you’re running at least 8.8.15.1643980846.p30-1.

LockBit 2.0

Because security professionals needed something else to keep us occupied, the LockBit ransomware campaign is back for a round two. This is another ransomware campaign run in the as-a-Service pattern — RAAS. LockBit 2 has caught enough attention, that the FBI has published a FLASH message (PDF) about it. That’s the FBI Liaison Alert System, in the running for the worst acronym. (Help them figure out what the “H” stands for in the comments below!)

Like many other ransomware campaigns, LockBit has a list of language codes that trigger a bail on execution — the Eastern European languages you would expect. Ransomware operators have long tried not to poison their own wells by hitting targets in their own back yards. This one is being reported as also having a Linux module, but it appears that is limited to VMWare ESXi virtual machines. A series of IoCs have been published, and the FBI are requesting any logs, ransom notes, or other evidence possibly related to this campaign to be sent to them if possible. Continue reading “This Week In Security: Zimbra, Lockbit 2, And Hacking NK” →

DIY Nanoleaf LED Panels Offer Peace Of Mind

February 11, 2022 by Lewin Day 14 Comments

Nanoleaf light panels are a popular product for creating glowing geometric designs on walls. However, for those that like to avoid IoT devices that integrate with big cloud services, they’re not ideal, and involve compromising on one’s privacy, somewhat. [Viktor] decided to build something of his own instead to avoid this problem.

The design is that of an equilateral triangle, which allows the panels to tesselate well. Each panel consists of two 3D printed parts. The black PLA base holds the WS2812B LED strips, cabling, and ESP8266 controller, while a white PLA cover goes over the top, which acts as a diffuser to spread the light from the individual LEDs. Each triangle contains 24 LEDs, and six triangles together consume around 1.6 amps when in use.

The benefit of the system is that it’s not controlled from a company’s cloud system, which can be shutdown at any time. [Viktor’s] setup runs entirely independently, and can be controlled from a simple web page. Plus, there’s nothing stopping him from modifying the code to use the panels for any purpose; commercial products like Nanoleaf don’t offer anywhere near the flexibility of building your own.

We’ve seen others build their own smart lighting with similar techniques before, too. Video after the break.

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