3D Print A Stenciling Frame For Your PCB

October 3, 2024 by 14 Comments

For many a hacker, stenciling a board for the first time is a game-changing experience – the solder joints you get, sure do give your PCB the aura of a mass-manufactured device. Now, you might not get a perfect print – and neither did [Atul R]. Not to worry, because if you have a 3D printer handy, he’s showing you how to design a 3D-printed frame using Blender and TinkerCAD, making your solder paste print well even if you’re trying to rest a giant stencil on top of a tiny board.

[Atul]’s situation was non-characteristic – the project is a 2mm thick PCB designed to plug right into a USB port, so the usual trick of using some scrap PCBs wouldn’t work, and using a 3D-printed frame turned out to be key. To get it done, he exported a .wrl from KiCad, processed it in Blender, and then designed a frame with help of TinkerCAD. These techniques, no doubt, will translate into your CAD of choice – especially if you go with .step export instead of .wrl.

This kind of frame design will get you far, especially for boards where the more common techniques fail – say, if you need to assemble a double-sided board and one side is already populated. Don’t have a stencil? You could surely make a 3D printed stencil, too, both for KiCad boards and for random Gerber files. Oh, and don’t forget this 3D-printable stencil alignment jig, while you’re at it – looks like it ought to save you quite a bit of trouble.

A Lightweight Balloon Tracker For High Altitude Missions

October 3, 2024 by 47 Comments

It’s pretty easy to take a balloon, fill it up with helium, and send it up in to the upper atmosphere. It’s much harder to keep track of it and recover it when it falls back to Earth. If you’re trying to do that, you might find some value in the Tiny4FSK project from the New England Weather Balloon Society.

Tiny4FSK is intended to be a very small solution for high-altitude tracking. As you might have guessed from the name, it communicates via 4FSK—four frequency shift keying. Basically, it communicates data via four separate tones. Based around the SAMD21G18A microcontroller, it’s designed to run on a single AA battery, which should last for anywhere from 10-17 hours. It communicates via a Si4063 transmitter set up to communicate on 433.2 MHz, using the Horus Binary v2 system. As for data, it’s hooked up with a GPS module and a BME280 environmental sensor for location. The balloon can figure out where it is, and tell you the temperature, pressure, and humidity up there, too.

If you’re looking for a lightweight balloon tracker, this one might be very much up your alley. We’ve featured other projects in this vein, too. Meanwhile, if you’re developing something new in the high-altitude ballooning space, you could keep it to yourself. Or, alternatively, you could tell us via the tipsline and we’ll tell everybody else. Your call!

Pulley System Makes Headphone Cables More Managable

October 3, 2024 by 13 Comments

It’s 2024. You’ve probably got one or more pairs of wireless headphones around the house. [Barnso] prefers wired headphones with a long cable, but he also decries the fact that it often gets tangled in his chair. The solution? A pulley system to make everything easier.

The concept is simple. [Barnso]’s system uses three pulleys. The headphone cable goes to the PC, and then runs over the first pulley. It then runs under a second pulley which is free to move, but weighted so that it naturally wants to fall down under gravity. The cable then comes back up over a third pulley, and then runs to the headphones on [Barnso]’s head. Basically, it’s a super simple cable retraction mechanism that keeps the long headphone cable organized and in one place.

It’s nice to see a simple mechanism that makes life easier, particularly one that solves a problem so many of us have faced in real life. The construction shown in the video is almost (intentionally?) maddeningly hacky but it does the job. If you prefer to go wireless, though, we can show you how to do that too.

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Supercon 2023: [Cory Doctorow] With An Audacious Plan To Halt The Internet’s Enshittification And Throw It Into Reverse

October 3, 2024 by 69 Comments

Those of us old enough to remember BBS servers or even rainbow banners often go down the nostalgia hole about how the internet was better “back in the day” than it is now as a handful of middlemen with a stranglehold on the way we interact with information, commerce, and even other people. Where’s the disintermediated future we were promised? More importantly, can we make a “new good web” that puts users first? [Cory Doctorow] has a plan to reverse what he’s come to call enshittification, or the lifecycle of the extractionist tech platform, and he shared it with us as the Supercon 2023 keynote.

As [Doctorow] sees it, there’s a particular arc to every evil platform’s lifecycle. First, the platform will treat its users fairly and provide enough value to accumulate as many as possible. Then, once a certain critical mass is reached, the platform pivots to exploiting those users to sell them out to the business customers of the platform. Once there’s enough buy-in by business customers, the platform squeezes both users and businesses to eke out every cent for their investors before collapsing in on itself.

Doctorow tells us, “Enshittification isn’t inevitable.” There have been tech platforms that rose and fell without it, but he describes a set of three criteria that make the process unavoidable.

  1. Lack of competition in the market via mergers and acquisitions
  2. Companies change things on the back end (“twiddle their knobs”) to improve their fortunes and have a united, consolidated front to prevent any lawmaking that might constrain them
  3. Companies then embrace tech law to prevent new entrants into the market or consumer rights (see: DMCA, etc.)

Continue reading “Supercon 2023: [Cory Doctorow] With An Audacious Plan To Halt The Internet’s Enshittification And Throw It Into Reverse” →

Two hands hold a rounded rectangular case with a small lollipop-shaped cutout. The case is dark grey with a bit of white protruding between the two halves in the middle.

Add USB-C To Your AirPods The Easy Way

October 3, 2024 by 8 Comments

While the death of Apple’s Lightning Connector can’t come soon enough, swapping the ports on their products as “category-defining innovations” seems a bit of a stretch. [Ken Pillonel] has designed a set of streamlined, repairable, USB-C adapters for the AirPods, AirPods Pro, and AirPods Max that show Apple what innovation really means.

If you’ve followed [Pillonel]’s work in the past, you’ll know he’s as a big a fan of repairability as we are here, so this isn’t just a cheap knockoff dongle that’ll be in the trash as fast as your counterfeit wireless earbuds. In the video below, he walks us through his quest start-to-finish to design something compact that gives you all the joys of USB-C without the pain of buying a whole new set of headphones.

We like the iteration on the connector, showing that flexible circuits can do some amazing things, but are still subject to failure at extreme angles. Using a combination of 3D printing, a cool robot sandblasting machine, a pick-and-place, and some old fashioned hand soldering, [Pillonel] treats us to a polished final product that’s put together with actual screws and not adhesive. His designs are all open source, so you can DIY, or he sells finished copies in his shop if you want to give one to your less-than-techy relatives.

[Pillonel] may seem familiar as he’s the guy who added USB-C to the iPhone before Apple and redesigned the AirPods Pro case for repairability. Apple is getting better about repair in some of its devices, for sure, but unsurprisingly, hackers do it better.

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Polaris Dawn, And The Prudence Of A Short Spacewalk

October 3, 2024 by 39 Comments

For months before liftoff, the popular press had been hyping up the fact that the Polaris Dawn mission would include the first-ever private spacewalk. Not only would this be the first time anyone who wasn’t a professional astronaut would be opening the hatch of their spacecraft and venturing outside, but it would also be the first real-world test of SpaceX’s own extravehicular activity (EVA) suits. Whether you considered it a billionaire’s publicity stunt or an important step forward for commercial spaceflight, one thing was undeniable: when that hatch opened, it was going to be a moment for the history books.

But if you happened to have been watching the live stream of the big event earlier this month, you’d be forgiven for finding the whole thing a bit…abrupt. After years of training and hundreds of millions of dollars spent, crew members Jared Isaacman and Sarah Gillis both spent less than eight minutes outside of the Dragon capsule. Even then, you could argue that calling it a spacewalk would be a bit of a stretch.

Neither crew member ever fully exited the spacecraft, they simply stuck their upper bodies out into space while keeping their legs within the hatch at all times. When it was all said and done, the Dragon’s hatch was locked up tight less than half an hour after it was opened.

Likely, many armchair astronauts watching at home found the whole thing rather anticlimactic. But those who know a bit about the history of human spaceflight probably found themselves unable to move off of the edge of their seat until that hatch locked into place and all crew members were back in their seats.

Flying into space is already one of the most mindbogglingly dangerous activities a human could engage in, but opening the hatch and floating out into the infinite black once you’re out there is even riskier still. Thankfully the Polaris Dawn EVA appeared to go off without a hitch, but not everyone has been so lucky on their first trip outside the capsule.

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Pi Zero Power Optimization Leaves No Stone Unturned

October 3, 2024 by 17 Comments

If you’ve ever designed a battery-powered device with a Pi Zero, you have no doubt looked into decreasing its power consumption. Generic advice, like disabling the HDMI interface and the onboard LED, is omnipresent, but [Manawyrm] from [Kittenlabs] goes beyond the surface-level, and gifts us an extensive write-up where every recommendation is backed with measurements. Armed with the Nordic Power Profiler kit and an SD card mux for quick experimentation, she aimed at two factors, boot time and power consumed while booting, and made sure to get all the debug information we could use.

Thanks to fast experimentation cycles and immediate feedback, we learn plenty of new things about what a Pi Zero does and when, and how we can tame various power-hungry aspects of its behavior. Disabling the GPU or its aspects like HDMI output, tweaking features like HAT and other peripheral probing, and even tactical overclocking during boot – it’s an extensive look at what makes a Pi Zero tick, and no chance for spreading baseless advice or myths.

All in all, this write-up helps you decrease the boot time from twelve seconds to just three seconds, and slash the power budget of the boot process by 80%. Some recommendations are as simple as config.txt entries, while others require you to recompile the kernel. No matter the amount of effort you can put into power optimization, you’ll certainly find things worth learning while following along, and [Manawyrm]’s effort in building her solar-powered Pi setup will help us all build better Pi-Zero-powered solar devices and handhelds.