Share Your Projects: KiCad Automations And Pretty Renders

March 11, 2024 by 23 Comments

I have a pretty large GitHub repository, with all of my boards open-sourced there. Now, I’m finally facing the major problem it has – it can be uncomfortable for others to work with. I don’t store Gerber files in the repository because that will interfere with how Git functions – you’re supposed to only have source files in the repo. Yet, when someone needs Gerbers for my PCB, or a schematic PDF, or just to see how the board looks before they clone the entire repository, I often don’t have a good option for them.

In my experience as a hacker, being able to find others’ PCBs on GitHub is simply wonderful, but a PCB repository without a README feels barren, and a PCB README without pictures makes me sad. On the other hand, not having these files autogenerate is uncomfortable – updating a picture every time is a major drawback in particular.

Let’s take a look at some KiCad Git integrations, and see what they have to offer.

kicad_cli

We’ve mentioned kicad_cli back when KiCad 7 got released, and in the recently released KiCad 8, it’s only become more powerful. Before, it could do gerbers and schematic PDFs, but now, it can even do DRC checks – which is ideal if you want to add a hook for any pull requests you might encounter.

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Generator Control Panel Unlocked With Reverse Engineering Heroics

March 11, 2024 by 11 Comments

Scoring an interesting bit of old gear on the second-hand market is always a bit of a thrill — right up to the point where you realize the previous owner set some kind of security code on it. Then it becomes a whole big thing to figure out, to the point of blunting the dopamine hit you got from the original purchase.

Fear not, though, because there’s dopamine aplenty if you can copy what [Buy it Fix it] did to decode the PIN on a used generator control panel. The panel appears to be from a marine generator, and while it powered up fine, the menu used to change the generator’s configuration options is locked by a four-digit PIN. The manufacturer will reset it, but that requires sending it back and paying a fee, probably considerable given the industrial nature of the gear.

Instead of paying up, [Buy it Fix it] decided to look for a memory chip that might store the PIN. He identified a likely suspect, a 24LC08B 8-Kb serial EEPROM, and popped it off to read its contents. Nothing was immediately obvious, but blanking the chip and reinstalling it cleared the PIN, so he at least knew it was stored on the chip. Many rounds of soldering and desoldering the chip followed, blanking out small sections of memory each time until the PIN was located. The video below edits out a lot of the rework, but gives the overall gist of the hack.

To be honest, we’re not sure if the amount of work [Buy it Fix it] put into this was less than taking a couple of hours to punch in PINs and brute-force it. Then again, if he hadn’t done the reverse engineering he wouldn’t have stumbled upon where the generator parameters like running time and power figures were stored. And it’s not really his style, either; we’ve seen him perform similar heroics on everything from tractors to solar inverters, after all.

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On An Aging Space Station, Air Leaks Become Routine

March 11, 2024 by 41 Comments

Anyone who’s ever owned an older car will know the feeling: the nagging worry at the back of your mind that today might be the day that something important actually stops working. Oh, it’s not the little problems that bother you: the rips in the seats, the buzz out of the rear speakers, and that slow oil leak that might have annoyed you at first, but eventually just blend into the background. So long as the car starts and can get you from point A to B, you can accept the sub-optimal performance that inevitably comes with age. Someday the day will come when you can no longer ignore the mounting issues and you’ll have to get a new vehicle, but today isn’t that day.

Looking at developments over the last few years one could argue that the International Space Station, while quite a bit more advanced and costly than the old beater parked in your driveway, is entering a similar phase of its lifecycle. The first modules of the sprawling orbital complex were launched all the way back in 1998, and had a design lifetime of just 15 years. But with no major failures and the Station’s overall condition remaining stable, both NASA and Russia’s Roscosmos space agency have agreed to several mission extensions. The current agreement will see crews living and working aboard the Station until 2030, but as recently as January, NASA and Roscosmos officials were quoted as saying a further extension isn’t out of the question.

Still, there’s no debating that the ISS isn’t in the same shape it was when construction was formally completed in 2011. A perfect case in point: the fact that the rate of air leaking out of the Russian side of the complex has recently doubled is being treated as little more than a minor annoyance, as mission planners know what the problem is and how to minimize the impact is has on Station operations.

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Reducing Seams In FDM Prints With Scarf Joint Seams

March 11, 2024 by 11 Comments

One unavoidable aspect of FDM 3D printing is that each layer consists out of one or more lines that have a beginning and an end. Where these join up, a seam is formed, which can be very noticeable if the same joint exists on successive layers. Taking a hint from woodworking, a possible solution is now being worked on that involves scarf joints. This research is covered by [Michael Laws] in a recent Teaching Tech video on YouTube, where he also details his own printing attempts with a custom 3D model, and a guide by [psiberfunk/Adam L].

The idea for a scarf joint was pitched practically simultaneously by [vgdh] on the PrusaSlicer GitHub, and [Noisyfox] on the OrcaSlicer GitHub. The basic idea follows the woodworking and metalworking version of a scarf joint, with the overlap between two discrete parts across two heavily tapered ends. As with the woodworking version, the FDM scarf joint is not a silver bullet, and with the under development OrcaSlicer builds a lot of the parameters are still being tweaked to optimize the result.

If it can be made to work, it could mean that scarf joints will soon be coming to an OrcaSlicer and PrusaSlicer release near you. Theoretically it should mean faster prints than with randomized seams as fewer print head adjustments are needed, and it may provide a smoother result. Definitely an interesting development that we hope to see come to fruition.

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Measuring Nanometers At Home

March 11, 2024 by 9 Comments

If someone asked you to measure a change in distance at about one ten thousandths of the diameter of a proton, you’d probably assume you would need access a high-tech lab. The job is certainly too tight for your cheap Harbor Freight calipers. [Opticsfan], though, has a way to help. You might not be able to get quite that close, but the techniques will allow you to measure a surprisingly small distance.

The technique requires a Fabry Perot cavity, an inexpensive spectrometer, and an online calculator to interpret the data. This type of cavity is two parallel mirrors facing each other with a slight gap between them. Light can only pass through the cavity when it is in resonance with the cavity. These have been around since 1899, so they aren’t that exotic. In fact, they are often used in laser communication systems, according to the post.

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μRepRap: Taking RepRap Down To Micrometer-Level Manufacturing

March 10, 2024 by 30 Comments

When the RepRap project was started in 2005 by [Dr Adrian Bowyer], the goal was to develop low-cost 3D printers, capable of printing most of their own components. The project slipped into a bit of a lull by 2016 due to the market being increasingly flooded with affordable FDM printers from a growing assortment of manufacturers. Now it seems that the RepRap project may have found a new impetus, in the form of sub-millimeter level fabrication system called the μRepRap as announced by [Vik Olliver] on the RepRap project blog, with accompanying project page.

The basic technology is based around the OpenFlexure project’s Delta Stage, which allows for very precise positioning of an imaging element, or conceivably a fabrication tool. As a first step, [Vik] upgrade the original delta stage to a much reinforced one that can accept larger NEMA17 stepper motors. This also allows for standard 3D printer electronics to control the system much like an FDM printer, only at much smaller scales and with new types of materials. The current prototype [Vik] made has a claimed step accuracy of 3 µm, with a range of tools and deposition materials being considered, including photosensitive resins.

It should be noted here that although this is a project in its infancy, it has solid foundations due to projects like OpenFlexure. Will μRepRap kickstart micrometer-level manufacturing like FDM 3D printing before? As an R&D project it doesn’t come with guarantees, but color us excited.

Thanks to [Tequin] for the tip.

Fastest FPV drone, pending official confirmation. (Credit: Luke Maximo Bell)

Got To Go Fast: The Rise Of Super-Fast FPV Drones

March 10, 2024 by 27 Comments

Generally when one considers quadcopter drones, the term ‘fast’ doesn’t come to mind, but with the rise of FPV  (First Person View) drones, they have increasingly been designed to go as fast as possible. This can be for competitive reasons, to dodge enemy fire on a battlefield, or in the case of [Luke Maximo Bell] to break the world speed record. Over the course of months he set out to design the fastest FPV drone, involving multiple prototypes, many test runs and one failed official speed run.

The components of the third FPV drone attempt, as used with the world record attempt. (Credit: Luke Maximo Bell)
The components of the third FPV drone attempt, as used with the world record attempt. (Credit: Luke Maximo Bell)

The basic design of these designed-for-speed FPV drones is more reminiscent of a rocket than a quadcopter, with the upside-down propellers  requiring the operator first lifting the drone into the air from an elevated position. After this the drone transitions into a level flight profile by rotating with the propellers pointing to the back. This gives the maximum thrust, while the body provides lift.

Although this seems simple, flying this type of drone is very hard, as it’s hard to tell what is happening, even when landing. [Luke] ended up installing a camera in the nose which can rotate to provide him with different angles. Tweaking the flight computer to deal with the control issues that occur at speeds above 300 km/h.

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