Engineering

581 Articles

The Real John Wick-Style Bullet Proof Suit

April 10, 2023 by 55 Comments

If you’ve seen the John Wick movies, you’ve probably had to suspend your disbelief about many things, but the bulletproof suits are perhaps the hardest thing to swallow. They look like stylish suits but are impervious to just about anything at any range. What’s more is when you are hit, they seem to absorb all impact with no effect on the wearer at all.

You can keep running, firing, or karate kicking while the suit takes all of the bullets. You can even pull your jacket up over your face if you want to protect that million-dollar smile. Physics, of course, tells us that a suit like this is pretty much impossible. Except that they actually exist. Granted, the real-life suits don’t have the magic physics-defying powers of Mr. Wick’s suit, but if you have the cash, you can get a smart-looking suit that protects you from getting killed by a bullet.

Real Life, Part I

In the movies, the suits supposedly have Kevlar in them just like a real piece of ballistic body armor. The problem is, Kevlar is bulky. However, most of the real body armor you see — like a vest on a SWAT team operative — is made from Kevlar or similar ballistic fibers like Twaron, Goldflex, or Dyneema. They also have plates made of metal or ceramic. Continue reading “The Real John Wick-Style Bullet Proof Suit” →

Self-Healing Concrete: What Ancient Roman Concrete Can Teach Us

April 3, 2023 by 30 Comments

Concrete is an incredibly useful and versatile building material on which not only today’s societies, but also the ancient Roman Empire was built. To this day Roman concrete structures can be found in mundane locations such as harbors, but also the Pantheon in Rome, which to this day forms the largest unreinforced concrete dome in existence at 43.3 meters diameter, and is in excellent condition despite being being nearly 1,900 years old.

Even as the Roman Empire fell and receded into what became the Byzantine – also known as the Eastern Roman – Empire and the world around these last remnants of Roman architecture changed and changed again, all of these concrete structures remained despite knowledge of how to construct structures like them being lost to the ages. Perhaps the most astounding thing is that even today our concrete isn’t nearly as durable, despite modern inventions such as reinforcing with rebar.

Reverse-engineering ancient Roman concrete has for decades now been the source of intense study and debate, with a recent paper by Linda M. Seymour and colleagues adding an important clue to the puzzle. Could so-called ‘hot mixing’, with pockets of reactive lime clasts inside the cured concrete provide self-healing properties?

Continue reading “Self-Healing Concrete: What Ancient Roman Concrete Can Teach Us” →

Tour A PCB Assembly Line From Your Armchair

April 2, 2023 by 15 Comments

Those of us who build our own electronics should have some idea of the process used to assemble modern surface-mount printed circuit boards. Whether we hand-solder, apply paste with a syringe, use a hotplate, or go the whole hog with stencil and oven, the process of putting components on boards and soldering them is fairly straightforward. It’s the same in an industrial setting, though perhaps fewer of us will have seen an industrial pick-and-place line in action. [Martina] looks at just such a line for us, giving a very accessible introduction to the machines and how they are used. Have a look, in the video below the break.

It’s particularly interesting as someone used to the home-made versions of these machines, to see the optical self-alignment and the multiple pick-and-place tools which are beyond the simpler pick-and-place machines you’ll find in a hackerspace. Multiple machines in a line are also beyond hackerspaces, so the revelation that the first machine is deliberately run slowly to avoid the line backing up is a valuable one.

At the end of the line is the reflow oven itself, through which the boards pass on a belt through carefully graded hot air zones. Certainly a step up from a toaster oven with an Arduino controller!

Sadly not all of us will be lucky enough to have such a line at our disposal, but pick-and-place projects come up here quite often. We did a teardown on the feeders from a Siemens machine a couple of years ago.

Continue reading “Tour A PCB Assembly Line From Your Armchair” →

Feeling The Heat: Railway Defect Detection

March 28, 2023 by 29 Comments

On the technology spectrum, railroads would certainly seem to skew toward the brutally simplistic side of things. A couple of strips of steel, some wooden ties and gravel ballast to keep everything in place, some rolling stock with flanged wheels on fixed axles, and you’ve got the basics that have been moving freight and passengers since at least the 18th century.

But that basic simplicity belies the true complexity of a railway, where even just keeping the trains on the track can be a daunting task. The forces that a fully loaded train can exert on not only the tracks but on itself are hard to get your head around, and the potential for disaster is often only a failed component away. This became painfully evident with the recent Norfolk Southern derailment in East Palestine, Ohio, which resulted in a hazardous materials incident the likes of which no community is ready to deal with.

Given the forces involved, keeping trains on the straight and narrow is no mean feat, and railway designers have come up with a web of sensors and systems to help them with the task of keeping an eye on what’s going on with the rolling stock of a train. Let’s take a look at some of the interesting engineering behind these wayside defect detectors.

Continue reading “Feeling The Heat: Railway Defect Detection” →

A freshly reballed BGA chip next to a clean PCB footprint

Working With BGAs: Soldering, Reballing, And Rework

March 23, 2023 by 31 Comments

In our previous article on Ball Grid Arrays (BGAs), we explored how to design circuit boards and how to route the signals coming out of a BGA package. But designing a board is one thing – soldering those chips onto the board is quite another. If you’ve got some experience with SMD soldering, you’ll find that any SOIC, TQFP or even QFN package can be soldered with a fine-tipped iron and a bit of practice. Not so for BGAs: we’ll need to bring out some specialized tools to solder them correctly. Today, we’ll explore how to get those chips on our board, and how to take them off again, without spending a fortune on equipment.

Tools of the Trade

For large-scale production, whether for BGA-based designs or any other kind of SMD work, reflow ovens are the tool of choice. While you can buy reflow ovens small enough to place in your workshop (or even build them yourself), they will always take up quite a bit of space. Reflow ovens are great for small-scale series production, but not so much for repairs or rework. Continue reading “Working With BGAs: Soldering, Reballing, And Rework” →

PCIe For Hackers: The Diffpair Prelude

March 14, 2023 by 35 Comments

PCIe, also known as PCI-Express, is a highly powerful interface. So let’s see what it takes to hack on something that powerful. PCIe is be a bit intimidating at first, however it is reasonably simple to start building PCIe stuff, and the interface is quite resilient for hobbyist-level technology. There will come a time when we want to use a PCIe chip in our designs, or perhaps, make use of the PCIe connection available on a certain Compute Module, and it’s good to make sure that we’re ready for that.

PCIe is everywhere now. Every modern computer has a bunch of PCIe devices performing crucial functions, and even iPhones use PCIe internally to connect the CPU with the flash and WiFi chips. You can get all kinds of PCIe devices: Ethernet controllers, high-throughput WiFi cards, graphics, and all the cheap NVMe drives that gladly provide you with heaps of storage when connected over PCIe. If you’re hacking on a laptop or a single-board computer and you’d like to add a PCIe device, you can get some PCIe from one of the PCIe-carrying sockets, or just tap into an existing PCIe link if there’s no socket to connect to. It’s been two decades since we’ve started getting PCIe devices – now, PCIe is on its 5.0 revision, and it’s clear that it’s here to stay.

Continue reading “PCIe For Hackers: The Diffpair Prelude” →

A Hacker’s Introduction To DIY Light Guide Plates

March 13, 2023 by 38 Comments

Last year, I found myself compelled to make a scaled-down replica of the iconic test chamber signs from the video game Portal. If you’ve played the game, you’ll remember these signs as the illuminated monoliths that postmarked the start of every test chamber. In hyperstylized video game fashion, they were also extremely thin.

Stay tuned for cake at the end of this article.

True to the original, my replica would need to be both slimmed down and backlit with a uniform, natural white glow. As fate would have it, the crux of this project was finding a way to do just that: to diffuse light coming in from the edges so that it would emit evenly from the front.

What I thought would be quick project ended up being a dive down the rabbit hole that yielded some satisfying results. Today, I’d like to share my findings and introduce you to light guide plates, one of the key building blocks inside of much of today’s backlit screen technology. I’ll dig into the some of the working principles, introduce you to my homebrew approach, and leave you with some inspirational source code to go forth and build your own. Continue reading “A Hacker’s Introduction To DIY Light Guide Plates” →