Scanning electron micrograph of a microfabricated lens array

Getting A Fly’s-Eye View With Microfabricated Lens Arrays

September 7, 2021 by 11 Comments

Atomic force microscopy, laser ablation, and etching with a witches brew of toxic chemicals: sounds like [Zachary Tong] has been playing in the lab again, and this time he found a way to fabricate arrays of microscopic lenses as a result.

Like many of the best projects, [Zach]’s journey into micro-fabrication started with a happy accident. It happened while he was working on metal-activated chemical etching (MACE), which uses a noble metal catalyst to selectively carve high-aspect-ratio features in silicon. After blasting at a silver-coated silicon wafer with a laser, he noticed the ablation pits were very smooth and uniform after etching. This led him to several hypotheses about what was going on, all of which he was able to test.

The experiments themselves are pretty interesting, but what’s really cool is that [Zach] realized the smooth hemispherical pits in the silicon could act as a mold for an array of microscopic convex lenses. He was able to deposit a small amount of clear silicone resin into the mold by spin-coating, and (eventually) transfer the microlens array to a glass slide. The lenses are impressively small — hundreds of them over only a couple hundred square microns — and pretty well-formed. There’s always room for improvement, of course, but for an initial attempt based on a serendipitous finding, we’d call it a win. As for what good these lenses are, your guess is as good as ours. But novel processes like these tend to find a way to be useful, and the fact that this is coming out of a home lab doesn’t change that fact.

We find this kind of micro-fabrication fascinating. Whether it’s making OLED displays, micro-machining glass with plasma, or even rolling your own semiconductors, we can’t get enough of this stuff.

Continue reading “Getting A Fly’s-Eye View With Microfabricated Lens Arrays” →

Hackaday Podcast 132: Laser Disco Ball, Moore’s Law In Your Garage, Cheap Cyborg Glasses, And A Mouse That Detects Elephants

August 20, 2021 by 3 Comments

Hackaday editors Elliot Williams and Mike Szczys debate the great mysteries of the hacking universe. On tap this week is news that Sam Zeloof has refined his home lab chip fabrication process and it’s incredible! We see a clever seismometer built from plastic pipe, a laser, and a computer mouse. There’s a 3D printed fabric that turns into a hard shell using the same principles as jamming grippers. And we love the idea of high-powered lasers being able to safely direct lighting to where you want it.

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!

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Garage Semiconductor Fab Gets Reactive-Ion Etching Upgrade

June 29, 2021 by 21 Comments

It’s a problem that few of us will likely ever face: once you’ve built your first homemade integrated circuit, what do you do next? If you’re [Sam Zeloof], the answer is clear: build better integrated circuits.

At least that’s [Sam]’s plan, which his new reactive-ion etching setup aims to make possible. While his Z1 dual differential amplifier chip was a huge success, the photolithography process he used to create the chip had its limitations. The chemical etching process he used is a bit fussy, and prone to undercutting of the mask if the etchant seeps underneath it. As its name implies, RIE uses a plasma of highly reactive ions to do the etching instead, resulting in finer details and opening the door to using more advanced materials.

[Sam]’s RIE rig looks like a plumber’s stainless steel nightmare, in the middle of which sits a vacuum chamber for the wafer to be etched. After evacuating the air, a small amount of fluorinated gas — either carbon tetrafluoride or the always entertaining sulfur hexafluoride — is added to the chamber. A high-voltage feedthrough provides the RF energy needed to create a plasma, which knocks fluorine ions out of the process gas. The negatively charged and extremely reactive fluorine ions are attracted to the wafer, where they attack and etch away the surfaces that aren’t protected by a photoresist layer.

It all sounds simple enough, but the video below reveals the complexity. There are a lot of details, like correctly measuring vacuum, avoiding electrocution, keeping the vacuum pump oil from exploding, and dealing with toxic waste products. Hats off to [Sam’s dad] for pitching in to safely pipe the exhaust gases through the garage door. This ties with [Huygens Optics]’s latest endeavor for the “coolest things to do with fluorine” award.

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Hackaday Links: April 18, 2021

April 18, 2021 by 14 Comments

More bad news from Mars this week, and this time not just from Perseverance. Last week the eagerly anticipated first flight of the helicopter Ingenuity was delayed for a couple of days after failing a full-speed spin-up test of its rotors. That appears to have been a bigger deal than initially thought, as it required a significant rewrite of the helicopter’s software. That meant testing, of course, and subsequent upload to the UAV, which at 174 million miles away takes a bit of doing. The good news is that they were able to complete the full-speed rotor test without the full program upload, so we’re one step closer to flight, which may take place as early as Monday morning.

Meanwhile, over at Elysium Planitia, the Mars InSight lander has troubles of its own. The geophysical laboratory, which has been trying to explore the inner structure of Mars since landing in 2018, entered an “emergency hibernation” state this week because of a lack of sufficient power generation. Unlike the radioisotope-powered Perseverance rover, InSight relies on a pair of solar panels for its electricity, and those panels are being obscured by Martian dust. The panels normally get blown clean by Martian winds, but things have been calm lately and the dust has really built up. If this seems like deja vu all over again, it’s probably because a planet-wide dust storm is what killed the plucky Opportunity rover back in 2018. Here’s hoping the wind picks up a little and InSight can get back to work.

Funny what crops up in one’s newsfeed, especially when one is responsible for putting out content that populates others’ newsfeeds. We recently took a look at the dangers of “zinc fever”, a flu-like illness that can crop up after inhaling gasses produced by molten zinc. That resulted in stumbling across an article from last year about mild steel welding fumes being classified as a human carcinogen. This comes from the Health and Safety Executive, a UK government agency concerned with workplace health issues. The release is an interesting read, and it suggests that mild steel fumes can cause not only lung cancer but kidney cancer. The announcement is mainly concerned with British workplaces, of course, but there are some interesting tidbits in there, such as the fact that welding fumes make dust particles so small that they can reach down into the very lowest reaches of lungs, the alveoli where gas exchange occurs. It’s enough to make one invest in PAPR or some kind of fume extractor.

For those of a certain vintage, our first computer was probably something that bore little resemblance to a PC or laptop. It was likely a single-board affair or something like a C64, and acquiring the essential bit of hardware usually left little in the budget for a proper monitor. Little 12″ B&W TVs were a dime a dozen, though, and easily — if grainily — enlisted into service as a monitor by way of an RF modulator. To recreate a little of that magic with modern hardware, Hackaday contributor Adam Zeloof came up with the PiMod Zero, an RF-modulator hat for the Raspberry Pi Zero that turns the component video into an NTSC analog signal. He’s open-sourced the design files, or there’s a CrowdSupply campaign for those who prefer to buy.

And finally, if you somehow traveled back in time to the 1940s with a laptop, how long would it have taken you to crack the Enigma code? Longer than you think, at least according to Dr. Mike Pound over at Computerphile, who released a fascinating video on how Enigma worked and what it took for Turing and the gang at Bletchley to crack the code. We knew some of the details of Enigma’s workings before seeing this video, but Mike’s explanation was really good. And, his explanation of the shortcut method he used to decode an Enigma message made the whole process clearer to us than it’s ever been. Interesting stuff.

Continue reading “Hackaday Links: April 18, 2021” →

ESP8266-Powered Receipt Printer Puts RESTful API On Dead Trees

March 10, 2021 by 1 Comment

Taking his digital information into the real-world, [Davide Gironi] has built his own note transcriber from a point-of-sale receipt printer and an ESP8266.

You’ve seen these receipt printers at the order window of restaurants. A server puts in an order from any of the machines throughout the restaurant and a paper summary spits out for the chef line to start in on (and even cuts itself off from the roll).  Why shouldn’t we have this convenience in our own lives?

The printer communicates using a variant of the Epson Standard Code for Printers, for which [Davide] has written a library and thankfully shared the code. Adding an ESP8266 using a couple voltage regulators and some passive components makes this wireless, except for power. It has all the fun bells and whistles to set up the WiFi credentials and once running, just push the button on the base and it’ll spit out your data.

But wait, where is that data coming from? The web-based settings page lets you configure a URI to the RESTful source of your choosing. (XKCD has one, don’t they?) It also lets you configure header, footer, error messages, and of course your company hacker logo.

One of our favorite receipt-printer moments was when Hackaday editor of yore [Eliot Phillips] brought a selfie receipt printer to Supercon. We couldn’t find any pictures of that one, so we’ll leave you with the excellent hack [Sam Zeloof] pulled off by cramming one of these into a Polaroid camera.

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A Scientist Made An Artificial Black Hole In The Lab, And You Won’t Believe What Happened Next

March 8, 2021 by 53 Comments

OK, that was a little click-baity, but then again, so was the announcement this week that a scientist had confirmed Hawking radiation with a lab-grown black hole. It sure got our attention, at least.

As it turns out, the truth is both less and more than meets the eye. The article above was eventually edited to better reflect the truth that, alas, we have not yet found a way to create objects so massive that even light cannot escape them. Instead, physicist [Jeff Steinhauer] and colleagues at the Technion-Israel Institute of Technology have developed an acoustic model of black holes, which is what was used to observe the equivalent of Hawking radiation for the first time. Hawking radiation is the theoretical exception to the rule that nothing makes it out of a black hole and would imply that black holes evaporate over time. The predicted radiation would be orders of magnitude weaker than the background radiation, though, making it all but impossible to detect.

That’s where [Steinhauer]’s sonic black holes come in. In these experiments, phonons, packets of mechanical vibrations that stand in for photons, are trapped in a fast-moving stream of fluid. The point in the stream where its speed straddles the local speed of sound is the equivalent to a real black hole’s event horizon; phonons inside that boundary can never escape. Except, of course, for the sonic equivalent of Hawking radiation, which the researchers found after 97,000 attempts.

When we first stumbled upon this story, we assumed a lab-grown black hole, even an acoustic analog, would take a CERN’s-worth of equipment to create. It turns out to be far simpler than that; [Steinhauer], in fact, built his black hole machine singlehandedly from relatively simple equipment. The experiments do require temperatures near absolute zero and a couple of powerful lasers, so it’s not exactly easy stuff; still, we can’t help but wonder if sonic black holes are within the reach of the DIY community. Paging [Ben Krasnow] and [Sam Zeloof], among others.

[Featured image credit: Nitzan Zohar, Office of the Spokesperson, Technion]

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Hackaday Links: December 20, 2020

December 20, 2020 by 11 Comments

If development platforms were people, Google would be one of the most prolific serial killers in history. Android Things, Google’s attempt at an OS for IoT devices, will officially start shutting down on January 5, 2021, and the plug will be pulled for good a year later. Android Things, which was basically a stripped-down version of the popular phone operating system, had promise, especially considering that Google was pitching it as a secure alternative in the IoT space, where security is often an afterthought. We haven’t exactly seen a lot of projects using Android Things, so the loss is probably not huge, but the list of projects snuffed by Google and the number of developers and users left high and dry by these changes continues to grow. Continue reading “Hackaday Links: December 20, 2020” →