Friday Hack Chat: Making And Breaking Hardware With Bunnie

February 8, 2017 by Brian Benchoff 5 Comments

This Friday, February 10th, at 9am PST, Hackaday.io will be graced with one of the greatest hardware creators in recent memory. [Bunnie Huang] will be talking about making and breaking hardware in the Hackaday.io Hack Chat.

[Bunnie] is a nearly peerless hardware hacker. He literally wrote the book on hacking the XBox, developed the Chumby, and developed the Novena, an open source Laptop. He’s torn down the Form 2 3D printer, explored the iPhone’s hackability with [Edward Snowden], wrote the book you want to have on your carryon when flying into Hong Kong, and recently released The Hardware Hacker, a retelling of his adventures in hardware hacking. He’s now working on the Love to Code platform.

[Bunnie] is a bridge across worlds. There is no one else so deeply embedded in the world of electronics manufacturing that is also willing to tell the world about what he’s found. If you want to learn about electronics, the Bunnie Studios blog is a mandatory read.

For this week’s Hack Chat, [Bunnie] will be taking questions from the Hackaday.io community. If you’ve ever wanted to know what it takes to build a few thousand things, this is the guy to ask.

Having trouble figuring out when 09:00 PST is in your local time zone? Here’s a countdown timer!

Here’s How To Take Part:

Buttons to join the project and enter the Hack Chat

Our Hack Chats are live community events on Hackaday.io Hack Chat group messaging. Log into Hackaday.io, visit that page, and look for the ‘Join this Project’ Button. Once you’re part of the project, the button will change to ‘Team Messaging’, which takes you directly to the Hack Chat.

You don’t have to wait until Friday; join whenever you want and you can see what the community is talking about.

Upcoming Hack Chats

These Hack Chats are a weekly thing, and we have a few more on the books. Next week, we’ll be covering RF design with [Jenny List], and later going over mechanical manufacturing with Fictiv. You can check out all the upcoming Hack Chats on this project.

MotorMouth For Future Artificial Humans

February 8, 2017 by Steven Dufresne 28 Comments

When our new computer overlord arrives it’ll likely give orders using an electromagnetic speaker (or more likely, by texting instead of talking). But for a merely artificial human being, shouldn’t we use an artificial mouth with vocal cords ~~chords~~, nasal cavity, tongue, teeth and lips? Work on such a thing is scarce these days, but [Martin Riches] developed a delightful one called MotorMouth between 1996 and 1999.

It’s delightful for its use of a Z80 processor and assembly language, things many of us remember fondly, as well as its transparent side panel, allowing us to see the workings in action. As you’ll see and hear in the video below, it works quite well given the extreme difficulty of the task.

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Santos Dumont And The Origins Of Aviation

February 8, 2017 by Manuel Rodriguez-Achach 58 Comments

The history of aviation is a fascinating one, spanning more than two thousand years starting from kites and tower jumping. Many hackers are also aviation fans, and the name of Alberto Santos Dumont may be familiar, but if not, here we talk about his role and accomplishments in the field. Santos Dumont is one of the few aviation pioneers that made contributions in both balloons, airships and heavier-than-air aircraft.

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How Commercial Printed Circuit Boards Are Made

February 8, 2017 by Jenny List 30 Comments

Most of us who have dabbled a little in electronics will have made our own printed circuit boards at some point. We’ll have rubbed on sticky transfers, laser-printed onto acetate, covered our clothing with ferric chloride stains, and applied ourselves to the many complex and tricky processes involved. And after all that, there’s a chance we’ll have ended up with boards that were over or under-etched, and had faults. For many the arrival of affordable online small-run professional PCB production from those mostly-overseas suppliers has been a step-change to our electronic construction abilities.

[Fran Blanche] used to make her own boards for her Frantone effects pedals, but as she admits it was a process that could at times be tedious. With increased production she had to move to using a board house, and for her that means a very high-quality local operation rather than one on the other side of the world. In the video below the break she takes us through each step of the PCB production process as it’s done by the professionals with a human input rather than by robots or ferric-stained dilettantes.

Though it’s twenty minutes or so long it’s an extremely interesting watch, as while we’re all used to casually specifying the parameters of the different layers and holes in our CAD packages we may not have seen how they translate to the real-world processes that deliver our finished boards. Some operations are very different from those you’d do at home, for example the holes are drilled as a first step rather than at the end because as you might imagine the through-plating process needs a hole to plate. The etching is a negative process rather than a positive one, because it serves to expose the tracks for the plating process before etching, and the plating becomes the etch resist.

If you’re used to packages from far afield containing your prototype PCBs landing on your doorstep as if by magic, take a look. It’s as well to know a little more detail about how they were made.

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DIY Thermal Camera That’s Better And Cheaper Than A FLIR

February 8, 2017 by Brian Benchoff 70 Comments

A few years ago, FLIR unleashed a new line of handheld thermal imagers upon the world. In a manufacturing triumph, the cheapest of these thermal imaging cameras contained the same circuitry as the one that cost six times as much. Much hacking ensued. Once FLIR figured out the people who would be most likely to own a thermal imaging camera can figure out how to upload firmware, the party was over. That doesn’t mean we’re stuck with crippled thermal imaging cameras, though: we can build our own, with better specs than what the big boys are selling.

[Max] has been working on his DIY thermal imager for a while now. We first saw it about a year ago, and the results were impressive. This thermal camera is built around the FLIR Lepton sensor, providing thermal images with a resolution of 60 by 80 pixels. These thermal images were combined with a VGA resolution camera to produce the very cool enhanced imagery the commercial unit will get you. There’s also a 1/4-20 threaded insert on the bottom of [Max]’s version, making it far more useful in any experimental setup.

Now [Max] has unleashed his DIY Thermocam on the world of Open Hardware, and anyone can build their own for about €400 (about $425). The components required for this build include a FLIR Lepton sensor easily sourced from the Digikey or GroupGets, an Arducam Mini, a Teensy 3.6, and a mishmash of components that are probably kicking around your parts drawers.

If you want an overview of this project before digging in, [Max] has a project overview (PDF warning) going over the build. This is one of the better DIY projects we’ve seen recently, and the documentation is fantastic. If you’re thinking about buying one of those fancy thermal imaging cameras, here you go — this one is just as good and half off.

Repairing Crystal Earpieces

February 7, 2017 by Al Williams 11 Comments

If you make crystal radios, you’ve probably got a few crystal earpieces. The name similarity is a bit coincidental. The crystal in a crystal radio was a rectifier (most often, these days, a germanium diode, which is, a type of crystal). The crystal in a crystal earpiece is a piezoelectric sound transducer.

Back in the 1960s, these were fairly common in cheap transistor radios and hearing aids. Their sound fidelity isn’t very good, but they are very sensitive and have a fairly high impedance, and that’s why they are good for crystal radios.

[Steve1001] had a few of these inexpensive earpieces that either didn’t work or had low sound output. He found the root cause was usually a simple problem and shares how to fix them without much trouble.

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Bus Pirate Commandeers I2C

February 7, 2017 by Bryan Cockfield 19 Comments

The Bus Pirate is one of our favorite tool for quick-and-dirty debugging in the microcontroller world. Essentially it makes it easy to communicate with a wide variety of different chips via a serial terminal regardless of the type of bus that the microcontroller uses. Although it was intended as a time-saving prototyping device, there are a lot of real-world applications where a Bus Pirate can be employed full-time, as [Scott] shows us with his Bus Pirate data logger.

[Scott] needed to constantly measure temperature, and the parts he had on hand included an LM75A breakout board that has a temperature sensor on board. These boards communicate with I2C, so it was relatively straightforward to gather data from the serial terminal. From there, [Scott] uses a Python script to automate the process of gathering the data. The process he uses to set everything up using a Raspberry Pi is available on the project site, including the code that he used in the project.

[Scott] has already used this device for a variety of different projects around his house and it has already proven incredibly useful. If you don’t already have a Bus Pirate lying around there are a few other ways to gather temperature data, but if you have an extra one around or you were thinking about purchasing one, then [Scott]’s project is a great illustration of the versatility of this device.