Journey Through The Inner Workings Of A PCB

December 10, 2019 by 20 Comments

Most electronics we deal with day to day are comprised of circuit boards. No surprise there, right? But how do they work? This might seem like a simple question but we’ve all been in the place where those weird green or black sheets are little slices of magic. [Teddy Tablante] at Branch Eduction put together a lovingly crafted walkthrough flythrough video of how PCB(A)s work that’s definitely worth your time.

[Teddy]’s video focuses on unraveling the mysteries of the PCBA by peeling back the layers of a smartphone. Starting from the full assembly he separates components from circuit board and descends from there, highlighting the manufacturing methods and purpose behind what you see.

What really stands out here is the animation; at each step [Teddy] has modeled the relevant components and rendered them on the PCBA in 3D. Instead of relying solely on hard to understand blurry X-ray images and 2D scans of PCBAs he illustrates their relationships in space, an especially important element in understanding what’s going on underneath the solder mask. Even if you think you know it all we bet there’s a pearl of knowledge to discover; this writer learned that VIA is an acronym!

If you don’t like clicking links you can find the video embedded after the break. Credit to friend of the Hackaday [Mike Harrison] for acting as the best recommendation algorithm and finding this gem.

Continue reading “Journey Through The Inner Workings Of A PCB” →

Hackaday Podcast 045: Raspberry Pi Bug, Rapidly Aging Vodka, Raining On The Cloud, And This Wasn’t A Supercon Episode

December 6, 2019 by 5 Comments

Hackaday editors Mike Szczys and Elliot Williams talk over the last three weeks full of hacks. Our first “back to normal” podcast after Supercon turns out to still have a lot of Supercon references in it. We discuss Raspberry Pi 4’s HDMI interfering with its WiFi, learn the differences between CoreXY/Delta/Cartesian printers, sip on Whiskey aged in an ultrasonic jewelry cleaner, and set up cloud printing that’s already scheduled for the chopping block. Along the way, you’ll hear hints of what happened at Supercon, from the definitive guide to designing LEDs for iron-clad performance to the projects people hauled along with them.

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!

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 (60 MB or so.)

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Continue reading “Hackaday Podcast 045: Raspberry Pi Bug, Rapidly Aging Vodka, Raining On The Cloud, And This Wasn’t A Supercon Episode” →

More Supercon Talks Taking The Hardware World By Storm

October 4, 2019 by 2 Comments

You’re going to love the talks at the Hackaday Superconference this November. The ultimate hardware conference is all about hardware creation. The ten speakers below join the talks we announced last week and that’s still not even half of what you’ll see on the stages of Supercon. Add to that the superb workshops we announced early this week and you begin to ask yourself just how much awesome can really fit into a single weekend. Well, it’s three full days and we’d recommend arriving the day before for the unofficial festivities too!

Of course, you’ll need a ticket to ride. At the time of writing there were some available (we’ve left the teens and are headed for single digits), but no guarantee there will be any left when this article is published. We’ll be maintaining a waiting list though, so if you’re sitting on a ticket you just can’t use, please return it so someone else can take your spot.

Enough delay, let’s see what talks await us at 2019 Supercon!

The Talks (Part Two of Many)


  • Shelley Green

    Pressure connections: crimping isn’t as simple as you thought.

    Crimping is generally defined as the joining of two conductors by mechanical forces. At first, the process appears to be rather simple. However, deeper investigations reveal complex dynamics that operate at macroscopic, microscopic, and nanoscales. I will cover the basic theory for pressure connections, examine the role of mechanical properties for both conductivity and tensile strength, look at oxides and surface films, and consider the design challenges for tooling, testing, and validation of crimp quality.


  • Mike Harrison

    Everything I’ve Learnt About LEDs.

    LEDs are not all created alike. I will cover a wide range of practical techniques involved in using LEDs, in particular in the context of large-scale installations, hower much of it will be equally applicable to smaller projects. Topics include suitable LED types, drive circuitry, dimming techniques, gamma correction. There will be live demonstrations illustrating many of the areas covered.


  • Kerry Scharfglass

    Basic Device Security for Basic Needs

    It feels like every day we hear about an unbelievable new security vulnerability that allows an attacker to spy on your dog through a connected light bulb or program your toaster oven remotely. Some of these are quite elaborate, requiring researchers years to track down. But others are total no-brainers; “why didn’t the manufacturer just do X!”. In our IoT-ified world device security is more important than ever, but not every hardware product needs to be secured like an ATM inside a missile. I will discuss basic design practices and implementation tricks which are easy to incorporate into your product and provide a solid baseline of security against casual adversaries.


  • Sophy Wong

    Made With Machines: 3D Printing & Laser Cutting for Wearable Electronics

    Building tech for the human body is tricky! Whether it’s a fitness tracker or a costume, making hardware comfortable and durable enough to wear is a fascinating design challenge. I like to tackle this challenge with the help of machines! In this talk, I’ll share my recent projects that use 3D printing and laser cutting to create wearable tech with precision and high impact. I’ll talk about the design process and build techniques for using 3D printing and laser cutting to create custom parts that are comfortable and perfect for wearables.


  • Jen Costillo

    The Future is Us: Why the Open Source And Hobbyist Community Will Drive Hi-Tech Consumer Products

    Where did we the OSHW and hobbyist community come from and what have we accomplished? The truth is we are driving modern consumer electronics industry. From prototyping, to tools to media and training, we have changed it all. I’ll talk about the reasons why, our impact and our future, as well as how to avoid becoming what the older industry is: obsolete.


  • Timothy Ansell

    Xilinx Series 7 FPGAs Now Have a Fully Open Source Toolchain!

    You should be super excited about FPGAs and how they allow open source projects to do hardware development. In this talk I will cover a basic introduction into what an FPGA is and can do, what an FPGA toolchain is, and how much things sucked when the only option was to use proprietary toolchains. The SymbiFlow project changed this and I’ll discuss what is currently supported including a demo of Linux on a RISC-V core with a cheap Xilinx FPGA development board.


  • Chris Gammell

    Gaining RF Knowledge: An Analog Engineer Dives into RF Circuits

    Starting my engineering career working on low level analog measurement, anything above 1kHz kind of felt like “high frequency”. This is very obviously not the case. I’ll go over the journey of discovering and rediscovering higher frequency techniques and squaring them with the low level measurement basics that I learned at the beginning my career. This will include a discussion of Maxwell’s equations and some of the assumptions that we make when we’re working on different types of circuits. You will find this information useful in the context of RF calculations around cellular, WiFi, Bluetooth and other commonly available communication methods.


  • Shanni Prutchi and Jeff Wood

    Adventures in Building Secure Networks from Blockchain Transactions

    In our talk, we will show how we designed and built a message authentication system operating on ADANA (Automated Detection of Anomalous Network Activity) and Hyperledger (a “smart contract” form of Blockchain) all hosted on just two servers that were no longer being used by Rowan College at Burlington County. The system was built using Docker, syslog-ng, Hyperledger Fabric and Composer, and a beta version of Splunk. This system is accessible by nodes wired into the network which interact with the hyperledger through a web browser. We’ll present the infrastructure of the network, details of the hyperledger, an explanation of all the tools used by the system, a walkthrough of how the system works, reflections on the particular challenges of this project, and what we see in the future of this technology.


  • John McMaster

    Replicating a Secure Telephone Key

    The STU-III secure telephone was originally developed by the NSA for defense use in the 1980’s but also saw use in unclassified commercial products like the Motorola Sectel 9600\. However, they require difficult to find electromechanical keys. I will describe the process of creating a compatible key for the Sectel 9600 by reverse engineering the mechanical and electrical design and subsequently fabricating it. Along the way I’ll discuss low volume manufacturing issues and strategies to overcome.

 

We Want You!

Don’t miss out. One weekend as one of so many amazing people will inspire you and recharge your creative batteries for the coming year of hardware hacking. See you at Supercon!

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Hackaday Links: September 8, 2019

September 8, 2019 by 7 Comments

We start this week with very sad news indeed. You may have heard about the horrific fire on the dive boat Conception off Santa Cruz Island last week, which claimed 33 lives. Sadly, we lost one of our own in the tragedy: Dan Garcia, author of the wildly popular FastLED library. Dan, 46, was an Apple engineer who lived in Berkley; his partner Yulia Krashennaya died with him. Our community owes Dan a lot for the work he put into FastLED over the last seven years, as many an addressable LED is being driven by his code today. Maybe this would be a good chance to build a project that uses FastLED and add a little light to the world, courtesy of Dan.

In happier news, the biggest party of the hardware hacking year is rapidly approaching. That’s right, the 2019 Hackaday Superconference will be upon us before you know it. Rumor has it that there aren’t that many tickets left, and we haven’t even announced the slate of talks yet. That’s likely to clean out the remaining stock pretty darn quickly. Are you seriously prepared to miss this? It seems like a big mistake to us, so why don’t you hop over and secure your spot before you’re crying into your Club-Mate and wondering what all the cool kids will be doing in November.

Of course one of the highlights of Superconference is the announcement of the Hackaday Prize winner. And while we naturally think our Prize is the best contest, that doesn’t mean there aren’t others worth entering. MyMiniFactory, the online 3D-printing community, is currently running a “Design with Arduino” competition that should be right up the alley of Hackaday readers. The goal is simple: submit a 3D-printed design that incorporates Arduino or other electronics. That’s it! Entries are accepted through September 16, so you’ve still got plenty of time.

Sometimes you see something that just floors you. Check out this tiny ESP32 board. It doesn’t just plug into a USB port – it fits completely inside a standard USB Type A jack. The four-layer board sports an ESP32, FTDI chip, voltage regulator, an LED and a ceramic antenna for WiFi and Bluetooth. Why would you want such a thing? Why wouldn’t you! The board is coming soon on CrowdSupply, so we hope to see projects using this start showing up in the tipline soon.

Here’s a “why didn’t I think of that?” bench tip that just struck us as brilliant. Ever had to probe a board to trace signal paths? It’s a common enough task for reverse engineering and repairs, but with increasingly dense boards, probing a massive number of traces is just too much of a chore. Hackaday superfriend Mike Harrison from “mikeselectricstuff” makes the chore easier with a brush made from fine stainless wires crimped into a ring terminal. Attached to one probe of a multimeter, the brush covers much more of the board at a time, finding the general area where your trace of interest ends up. Once you’re in the neighborhood you can drop back to probing one pad at a time. Genius! We’d imagine a decent brush could also be made from a bit of coax braid too.

Another shop tip to wrap up this week, this one for woodworkers and metalworkers alike. Raw materials are expensive, and getting the most bang for your buck is often a matter of carefully laying out parts on sheet goods to minimize waste. Doing this manually can be a real test of your spatial relations skills, so why not automate it with this cut list optimizer? The app will overlay parts onto user-defined rectangles and snuggle them together to minimize waste. The program takes any units, can account for material lost to kerfs, and will even respect grain direction if needed. It’s built for wood, but it should prove useful for sheet metal on a plasma cutter, acrylic on a laser, or even PCBs on a panel.

An Even Smaller World’s Smallest LED Blinky

April 11, 2019 by 14 Comments

Everything can be done with a 555. It’s a universal law, as all readers know. And a flashing light, you might think, will have been done before many times. But nobody has ever created a 555 flashing light as small as thie one created by [TWires], who has taken a TI LMC555 chip-scale packaged 555 and dead-bugged a working flasher on its surface using 01005 discrete components. There is a video showing it in operation that we’ve placed below the break, and it’s tiny. We probably all consider ourselves to be quite good at soldering, but this piece of work is in another class entirely.

The project was inspired by [Mike Harrison]’s previous holder of the smallest blinky prize, which used a PIC microcontroller atop a tiny surface mount supercapacitor. It uses the same capacitor for power, but we’d say it’s taken the blinky to new levels of tininess. Does this mean a new arms race is upon us in the world of tiny blinkies? We hope so, and though it’s difficult to imagine they can get much smaller we can’t wait to see what people come up with. If there’s one thing about our community it’s that saying something can’t be done is unwise: one of you will find a way if it is at all possible. Even Microchip’s MIC1555 might be a bit big though, so something inventive is called for.

For a fascinating run-down of the state of the 555 art, read this article from our own [Ted Yapo].

Continue reading “An Even Smaller World’s Smallest LED Blinky” →

Hackaday Podcast 006: Reversing IPod Screens, Hot Isotopes, We <3 Parts, And Biometric Toiletseats

February 15, 2019 by 2 Comments

What’s the buzz in the hackersphere this week? Hackaday Editors Elliot Williams and Mike Szczys recap their favorite hacks and articles from the past seven days. In Episode Six we cover an incredible reverse engineering effort Mike Harrison put in with iPod nano replacement screens. We dip our toes in the radioactive world of deep-space power sources, spend some time adoring parts and partsmakers, and take a very high-brow look at toilet-seat technology. In our quickfire hacks we discuss coherent sound (think of it as akin to laminar flow, but for audio), minimal IDEs for embedded, hand-tools for metalwork, and the little ESP32 bot that could.

Links for all discussed on the show are found below. As always, join in the comments below as we’ll be watching those as we work on next week’s episode!

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 (60 MB or so.)

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Continue reading “Hackaday Podcast 006: Reversing IPod Screens, Hot Isotopes, We <3 Parts, And Biometric Toiletseats” →

Putting An Out Of Work IPod Display To Good Use

February 12, 2019 by 10 Comments

[Mike Harrison] produces so much quality content that sometimes excellent material slips through the editorial cracks. This time we noticed that one such lost gem was [Mike]’s reverse engineering of the 6th generation iPod Nano display from 2013, as caught when the also prolific [Greg Davill] used one on a recent board. Despite the march of progress in mobile device displays, small screens which are easy to connect to hobbyist style devices are still typically fairly low quality. It’s easy to find fancier displays as salvage but interfacing with them electrically can be brutal, never mind the reverse engineering required to figure out what signal goes where. Suffice to say you probably won’t find a manufacturer data sheet, and it won’t conveniently speak SPI or I2C.

After a few generations of strange form factor exploration Apple has all but abandoned the stand-alone portable media player market; witness the sole surviving member of that once mighty species, the woefully outdated iPod Touch. Luckily thanks to vibrant sales, replacement parts for the little square sixth generation Nano are still inexpensive and easily available. If only there was a convenient interface this would be a great source of comparatively very high quality displays. Enter [Mike].

Outer edge of FPGA and circuit

This particular display speaks a protocol called DSI over a low voltage differential MIPI interface, which is a common combination which is still used to drive big, rich, modern displays. The specifications are somewhat available…if you’re an employee of a company who is a member of the working group that standardizes them — there are membership discounts for companies with yearly revenue below $250 million, and dues are thousands of dollars a quarter.

Fortunately for us, after some experiments [Mike] figured out enough of the command set and signaling to generate easily reproduced schematics and references for the data packets, checksums, etc. The project page has a smattering of information, but the circuit includes some unusual provisions to adjust signal levels and other goodies so try watching the videos for a great explanation of what’s going on and why. At the time [Mike] was using an FPGA to drive the display and that’s certainly only gotten cheaper and easier, but we suspect that his suggestion about using a fast micro and clever tricks would work well too.

It turns out we made incidental mention of this display when covering [Mike]’s tiny thermal imager but it hasn’t turned up much since them. As always, thanks for the accidental tip [Greg]! We’re waiting to see the final result of your experiments with this.