Cover Your Glass: A Lesson In Design Trades

February 12, 2016 by 25 Comments

Penn and Teller once had a show about “What is the best?” Engineers know that’s not a complete question. Think about a car. What makes the “best” car? It depends on why you want a car. For a race car driver, it might be that speed is the most important factor. A mom might value safety. Someone who commutes four hours a day might like a car that’s comfortable. A teenager wants something affordable.

If you think about it, though, it is even more complicated than that. For example, just about everyone wants a car that is safe. Reliability is pretty important, too. So the reality is, most people want a car that has multiple attributes. Worse still, they sometimes conflict; making one better will make some other ones worse. Mom wants a safe car, but not one that takes half a day to drive to the corner market. Nor does she want to pay a half million dollars for a safe car.

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Using Photogrammetry To Design 3D Printed Parts

February 12, 2016 by 33 Comments

[Stefan] is building a fixed wing drone, and with that comes the need for special mounts and adapters for a GoPro. The usual way of creating an adapter is pulling out a ruler, caliper, measuring everything, making a 3D model, and sending it off to a 3D printer. Instead of doing things the usual way, [Stefan] is using photogrammetric 3D reconstruction to build a camera adapter that fits perfectly in his plane and holds a camera securely.

ScanPhotogrammetry requires taking a few dozen pictures with a camera, using software to turn these 2D images into a 3D model, and building the new part from that model. The software [Stefan] is using is Pix4D, a piece of software that is coincidentally used to create large-scale 3D models from drone footage.

With the 2D images turned into a 3D model, [Stefan] imported the .obj file into MeshLab where the model could be cropped, smoothed, and the file size reduced. From there, creating the adapter was as simple as a little bit of OpenSCAD and sending the adapter model off to a 3D printer.

Just last week we saw photogrammetry used in another 3D object scanner. The results from both of these projects show real promise for modeling, especially with objects that are difficult to measure by hand.

Simple Headphone Bracket Shows Off Carbon Fiber Basics

February 12, 2016 by 12 Comments

The carbon fiber look is a pretty hot design element for things these days. Even things that have no need for the strength and flexibility of carbon fiber, from phone cases to motorcycle fenders, are sporting that beautiful glossy black texture. Some of it only looks like the real stuff, though, so it’s refreshing to see actual carbon fiber used in a project, like this custom headphone rack.

True, this is one of those uses of carbon fiber that doesn’t really need it – it just looks cool. But more importantly, [quada03]’s build log takes us through the whole process, from design to mold construction to laying up the fiber mats and finishing, and shows us how specialized equipment is not needed to achieve a great result. A homemade CNC router carves the two-piece mold out of Styrofoam, which is then glued up and smoothed over with automotive body filler. The epoxy-soaked carbon fiber mats are layered into the mold with careful attention paid to the orientation of the fibers, and the mold goes into one of those clothes-packing vacuum bags for 24 hours of curing. A little trimming and sanding later and the finished bracket looks pretty snazzy.

We’ve discussed the basics of carbon fiber fabrication before, but what we like about [quada03]’s build is that it shows how approachable carbon fiber builds can be. Once you hone your skills, maybe you’ll be ready to tackle a carbon fiber violin.

[via r/DIY]

KiCad Traducido Al Español

February 11, 2016 by 67 Comments

KiCad ya es una gran herramienta para la captura esquemática y el diseño de PCB, pero el software sólo funciona si es posible utilizarlo. Para los mil millones de personas que no hablan inglés, esto significa que el idioma es la barrera más grande al momento de utilizar el mejor software para desarrollo de hardware. En los últimos meses, [ElektroQuark] ha estado liderando esfuerzos de localización al español de KiCad y estos se encuentran finalmente completados. También ha iniciado un foro de KiCad en idioma español para llevar el desarrollo de software hacia uno de los idiomas más hablado del planeta.

SpanishMientras que ha habido otros intentos por localizar KiCad a otros idiomas, la mayoría de estos proyectos se encuentran incompletos. En una actualización de KiCad hace algunos meses, la localización al español ya contaba con algunas cadenas ya traducidas, pero no demasiadas. Los esfuerzos de [ElektroQuark] han acercado KiCad a millones de hablantes nativos de español, no solo algunos de sus menús.

El español es la segunda lengua más hablada del planeta, mientras que el inglés es la tercera. Teniendo en cuenta solamente este hecho, parece absurdo que casi todas las herramientas de software para capturas esquemáticas y diseño de PCB sean localizados sólo al chino o al inglés. Los esfuerzos de [ElektroQuark] por localizar KiCad al español son un gran avance para un ya impresionante software.

Lego Gaming Computer Case

February 11, 2016 by 37 Comments

Lego isn’t the first material that springs to mind when you think about building a new gaming computer case, but it does make sense when you think about it. It is easy to work with, can be easily reconfigured, and it’s pretty cheap. That’s the idea behind this very cool (no pun intended) gaming computer case build by [Mike Schropp]. Built around a Skylake i7 CPU and an NVidia 980 Ti graphics card, his build has an unusual X-shaped design that allows for plenty of airflow. The sides of the X hold the CPU cooler, the power supply, the hard drives and the graphics card cooler, so each of them has its own separate flow of cool air from the outside. That avoids the common problem of hot air from one component being passed over another, so it doesn’t get cooled properly. Critically for a gaming system, this design keeps all of the components much cooler than a more traditional case, which makes for more overclocking potential.

At the moment, [Mike] says he is struggling to keep up with the demand for people who want to buy custom versions of his build, but he is planning to release the details soon. “Initially that will probably be in the form of a DIY kit, where you can buy the plans with all the Lego bricks needed for the build, in a kit form” he told us. “Then you can add your own computer components to complete your build. At some point I’ll probably also just offer the plans themselves and allow the end-user to acquire the Lego bricks needed.”

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Dry Ice Is Nice For Separating Broken Phone Screens

February 11, 2016 by 29 Comments

Smartphones are the opium of the people. If you need proof, just watch the average person’s reaction when they break “their precious”. Repairing smartphones has become a huge business. The most often broken item on phones is of course the front glass. In most cases, the screen itself doesn’t break. On newer smartphones, even the touchscreen is safe. The front glass is only a protective lens.

The easiest way to repair a broken front glass is to swap the entire LCD assembly. For an iPhone 6 plus, this will run upwards of $120 USD. However, the glass lens alone is just $10. The problem is that the LCD, digitizer and front glass are a laminated package. Removing them without breaking the wafer thin LCD glass requires great care. The hardest part is breaking down the optical glue securing the glass to the LCD. In the past that has been done with heat. More recently, companies from China have been selling liquid-nitrogen-based machines that cool the assembly. Now immersing a phone screen in -196° C liquid nitrogen would probably destroy the LCD. However, these machines use a temperature controller to keep a surface at -140° C. Just enough to cause the glue to become brittle, but not kill the LCD.

[JerryRigEverything] doesn’t have several thousand dollars for a liquid nitrogen machine, but he does have a $5 block of dry ice. Dry ice runs at -78.5°C. Balmy compared to liquid nitrogen, but still plenty cold. After laying the phone screens down on the ice for a few minutes, [Jerry] was able to chip away the glass. It definitely takes more work than the nitrogen method. Still, if you’re not opening your own phone repair shop, we think this is the way to go.

Broken phones are a cheap and easy way to get high-resolution LCD screens for your projects. The problem is driving them. [Twl] has an awesome project on Hackaday.io for driving phone screens using an FPGA. We haven’t seen it done with iPhone 6 yet though. Anyone up for the challenge?

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Unlocking Thinkpad Batteries

February 11, 2016 by 66 Comments

A few months ago, [Matt] realized he needed another battery for his Thinkpad X230T. The original battery would barely last 10 minutes, and he wanted a battery that would last an entire plane flight. When his new battery arrived, he installed it only to find a disturbing message displayed during startup: “The system does not support batteries that are not genuine Lenovo-made or authorized.” The battery was chipped, and now [Matt] had to figure out a way around this.

Most recent laptop batteries have an integrated controller that implements the Smart Battery Specification (SBS) over the SMBus, an I2C-like protocol with data and clock pins right on the battery connector. After connecting a USBee logic analyser to the relevant pins, [Matt] found the battery didn’t report itself correctly to the Thinkpad’s battery controller.

With the problem clearly defined, [Matt] had a few options open to him. The first was opening both batteries, and replacing the cells in the old (genuine) battery with the cells in the newer (not genuine) battery. If you’ve ever taken apart a laptop battery, you’ll know this is the worst choice. There are fiddly bits of plastic and glue, and if you’re lucky enough to get the battery apart in a reasonably clean matter, you’re not going to get it back together again. The second option was modifying the firmware on the non-genuine battery. [Charlie Miller] has done a bit of research on this, but none of the standard SBS commands would work on the non-genuine battery, meaning [Matt] would need to take the battery apart to see what’s inside. The third option is an embedded controller that taps into the SMBus on the charger connector, but according to [Matt], adding extra electronics to a laptop isn’t ideal. The last option is modifying the Thinkpad’s embedded controller firmware. This last option is the one he went with.

There’s an exceptionally large community dedicated to Thinkpad firmware hacks, reverse engineering, and generally turning Thinkpads into the best machines they can be. With the schematics for his laptop in hand, [Matt] found the embedded controller responsible for battery charging, and after taking a few educated guesses had some success. He ran into problems, though, when he discovered some strangely encrypted code in the software image. A few Russian developers had run into the same problem, and by wiring up a JTAG to the embedded controller chip, this dev had a fully decrypted Flash image of whatever was on this chip.

[Matt]’s next steps are taking the encrypted image and building new firmware for the embedded controller that will allow him to charge is off-brand, and probably every other battery on the planet. As far as interesting mods go, this is right at the top, soon to be overshadowed by a few dozen comments complaining about DRM in batteries.