Test PCBs On A Bed Of Nails

February 9, 2019 by 35 Comments

While it might be tempting to start soldering a circuit together once the design looks good on paper, experience tells us that it’s still good to test it out on a breadboard first to make sure everything works properly. That might be where the process ends for one-off projects, but for large production runs you’re going to need to test all the PCBs after they’re built, too. While you would use a breadboard for prototyping, the platform you’re going to need for quality control is called a “bed of nails“.

This project comes to us by way of [Thom] who has been doing a large production run of circuits meant to drive nixie tubes. After the each board is completed, they are laid on top of a number of pins arranged to mate to various points on the PCB. Without needing to use alligator clamps or anything else labor-intensive to test, this simple jig with all the test points built-in means that each board can be laid on the bed and tested to ensure it works properly. The test bed looks like a bed of nails as well, hence the name.

There are other ways of testing PCBs after production, too, but if your board doesn’t involve any type of processing they might be hard to implement. Nixie tubes are mostly in the “analog” realm so this test setup works well for [Thom]’s needs.

A Trove Of Cosplay Prop Making Tutorials And Blueprints

February 9, 2019 by 5 Comments

[CutTransformGlue] recently posted a build video for “Making Rey’s Star Wars Blaster“, embedded after the break. The construction uses layered MDF sheets to build up the blaster, and it’s a treat to see it taking shape, ending with an amazing paint job. It’s a good way to learn about the techniques used to bring such props to life and help you hone your skills. But digging deeper led us down an awesome rabbit hole.

[CutTransformGlue] got plans for Rey’s Blaster from the Punished Props Academy – a prop and costume making team from Seattle committed to “transforming passionate fans into confident, skillful makers”. These folks have built a wide variety of projects ranging from guns, weapons, costumes, props and more, and are obviously extremely skilled at what they do. But they aren’t keeping those skills to themselves and in a series of posts and videos they are sharing with us such varied skills as Foamsmithing (gotta love that coinage), Molding, Casting, Painting, 3D printing, Vacuum Forming and electronics. If you’d like more information about supplies, check out the Tools and Materials section. And if all of this has given you the itch to build a Skyrim Wuuthrad or a Halo4 Sniper Rifle, head over to the amazing Free Blueprints section for a treasure chest full of downloads.

Like we said earlier, if building such stuff is your thing, it’s a rabbit hole from which you’ll find it extremely difficult to extract yourself. Have fun.

Continue reading “A Trove Of Cosplay Prop Making Tutorials And Blueprints” →

Simple Hand Tools Turn Brass And Steel Into An Amazing Astrolabe

February 9, 2019 by 12 Comments

There’s something enchanting about ancient tools and instruments. The idea that our forebears were able to fashion precision mechanisms with nothing but the simplest hand tools is fascinating. And watching someone recreate the feat, such as by building an astrolabe by hand, can be very appealing too.

The astrolabe is an ancient astronomical tool of incredible versatility, allowing the user to do everything from calculating when the sun will rise to predicting the positions of dozens of stars in the night sky. That it accomplishes all this with only a few moving parts makes it all the more fascinating. [Uri Tuchman] began the astrolabe build shown in the video below with only a few hand tools. He quickly had his fill of the manual fretsaw work, though, and whipped up a simple scroll saw powered by an old sewing machine foot treadle to speed up his work. The real treat though is the hand engraving, a skill that [Uri] has clearly mastered. We couldn’t help musing that a CNC router could do the same thing so much more quickly, but watching [Uri] do it was so much more satisfying. Everything about the build really makes a statement, from the contrasting brass and steel parts to the choice of complex Arabic script for the markings. [Uri] has another video that goes over astrolabe basics and his design process that’s well worth watching too.

While it’s nowhere near as complicated an instrument, this astrolabe puts us in the mood to watch the entire Clickspring clock build again. And [Chris] is working on his own ancient instrument build at the moment, recreating the Antikythera mechanism. We can’t wait to binge-watch that one too.

Continue reading “Simple Hand Tools Turn Brass And Steel Into An Amazing Astrolabe” →

Spectrometer Is Inexpensive And Capable

February 9, 2019 by 14 Comments

We know the effect of passing white light through a prism and seeing the color spectrum that comes out of the other side. It will not be noticeable to the naked eye, but that rainbow does not fully span the range of [Roy G. Biv]. There are narrowly absent colors which blur together, and those missing portions are a fingerprint of the matter the white light is passing through or bouncing off. Those with a keen eye will recognize that we are talking about spectrophotometry which is identifying those fingerprints and determining what is being observed and how much is under observation. The device which does this is called a spectrometer and [Justin Atkin] invites us along for his build. Video can also be seen below.

Along with the build, we learn how spectrophotometry works, starting with how photons are generated and why gaps appear in the color spectrum. It is all about electrons, which some of our seasoned spectrometer users already know. The build uses a wooden NanoDrop style case cut on a laser engraver. It needs some improvements which are mentioned and shown in the video so you will want to have some aluminum tape on hand. The rest of the bill of materials is covered including “Black 2.0” which claims to be the “mattest, flattest, black acrylic paint.” Maybe that will come in handy for other optical projects. It might be wise to buy first surface mirrors cut to size, but you can always make bespoke mirrors with carefully chosen tools.

Continue reading “Spectrometer Is Inexpensive And Capable” →

TréPhonos Calls Up History In Houston

February 8, 2019 by 7 Comments

Houston’s historic third ward, aka “The Tre,” is ripe rife with history, and some of that history is digitally preserved and accessible through an art installation in the form of repurposed payphones. We love payphones for obvious reasons and seeing them alive and kicking warms our hearts. Packing them with local history checks even more boxes. Twenty-four people collaborated to rebuild the three phones which can be seen in the video after the break, including three visual artists, three ambassadors, and eighteen residents who put their efforts into making the phones relevant not only to the ward but specifically to the neighborhood. One phone plays sound clips from musicians who lived or still live in the ward, another phone has spoken word stories, and the third has field recordings from significant locations in The Tre.

Each phone is powered by a solar cell and a USB battery pack connected to a Teensy with an audio adapter board, and a 20 watt amplifier. Buttons 1-9 play back recorded messages exclusive to each phone, star will record a message, and zero will play back the user-recorded message. Apps for smart phones are easy for young folks to figure out but the payphones ensure that these time capsules can be appreciated by people of any age, regardless of how tech savvy they are and that is wise as well as attractive. The coin return lever and coin slot also have associated sound clips unlike regular payphones so the artists get extra credit.

Did we say that we love payphones? Yes, yes we did. The very first post on Hackday was for a redbox and that got the ball rolling.

Continue reading “TréPhonos Calls Up History In Houston” →

A Tiny IDE For Your ATtiny

February 8, 2019 by 23 Comments

When writing code for the ATtiny family of microcontrollers such as a the ATtiny85 or ATtiny10, people usually use one of two methods: they either add support for the chip in the Arduino IDE, or they crack open their text editor of choice and do everything manually. Plus of course there are the stragglers out there using Eclipse. But [Wayne Holder] thinks there’s a better way.

The project started out as a simple way for [Wayne] to program the ATtiny10 in C under Mac OS, but has since evolved into an open source, cross-platform integrated development environment (IDE) for programming a wide range of ATtiny chips in C, C++, or Assembly. Not only does it integrate the source code editor and programmer, but it even bundles in documentation for common variants of the chips including block diagrams and pinouts; making it a true one-stop-shop for ATtiny hacking.

His IDE runs under Java, including OpenJDK, and [Wayne] provides a stable pre-built executable for those who don’t want to clone the whole GitHub repository. He’s included the GNU/AVR toolchains, though notes that testing so far has been limited to Mac OS, and he’s interested in feedback from Windows and Linux users. Assembly is done either with GNU AVR-AS, or an assembler of his own design, though the latter is currently limited to the ATTiny10.

To actually get the code onto the chip, the IDE supports using the Arduino as a programmer as well as dedicated hardware like the BusPirate or the USBasp. If you go the Arduino route, [Wayne] has even come up with a little adapter board which he’s made available through OSH Park to help wrangle the diminutive chips.

The ATtiny10 might have something of a learning curve, but in exchange this family of tiny microcontrollers offers an incredible amount of capability. When you’re working with what’s essentially a programmable grain of rice, the only limit is your own creativity.

Drone Gives Up Its Wireless Secrets To Zigbee Sniffer

February 8, 2019 by 2 Comments

There’s something thrilling about decoding an unknown communications protocol. You start with a few clues, poke at the problem with some simple tools, and eventually work your way up to that first breakthrough that lets you crack the code. It can be frustrating, but when you eventually win, it can be very rewarding.

It seems that [Jason] learned this while decoding the wireless conversation between his mass-market quad and its controller. The quad in question, a Yuneec Q500, is one of those mid-range, ready-to-fly drones that’s targeted at those looking to get in the air easily and take some cool pictures. Unsure how the drone and controller were talking, [Jason] popped the covers and found a Zigbee chipset within. With the help of a $14 Zigbee USB dongle and some packet sniffing software from TI, [Jason] was able to see packets flowing, but decoding them was laborious. Luckily, the sniffer app can be set up to stream packets to another device, so [Jason] wrote a program to receive and display packets. He used that to completely characterize each controller input and the data coming back from the drone. It’s a long and strange toolchain, but the upshot is that he’s now able to create KML in real time and track the drone on Google Earth as it flies. The video below shows the build and a few backyard test flights.

Congratulations to [Jason] for breaking the protocol and opening up drones like this for other hackers. If you’re interested in learning more about Zigbee sniffing, you can actually hack a few smarthome gadgets into useful sniffers.

Continue reading “Drone Gives Up Its Wireless Secrets To Zigbee Sniffer” →