Guide: Why Etch A PCB When You Can Mill?

January 4, 2018 by Adil Malik 83 Comments

I recall the point I started taking electronics seriously, although excited, a sense of dread followed upon the thought of facing the two main obstacles faced by hobbyists and even professionals: Fabricating you own PCB’s and fiddling with the ever decreasing surface mount footprints. Any resistance to the latter proves futile, expensive, and frankly a bit silly in retrospect. Cheap SMD tools have made it extremely easy to store, place, and solder all things SMD.

Once you’ve restricted all your hobbyist designs/experiments to SMD, how do you go about producing the PCBs needed for prototyping? Personally, I dread the thought of etching my own boards. The process is laborious and involves messy chemicals and specially sensitized PCB’s — none of which interest me. I’ve only ever done it a few times, and have promised myself never to do it again. Professional but cheap PCB manufacturing is more like it board pooling services such as OSH park have made this both easy and affordable — if you can wait for the turnaround.

So what are the alternatives? If you are really serious about swift prototyping from your own Lab, I put forth the case of milling your own PCB’s. Read on as I take you through the typical workflow from design to prototype and convince you to put up with the relatively high start up cost of purchasing a PCB mill.

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Upgrading A 3D Printer With OctoPrint

January 3, 2018 by Tom Nardi 56 Comments

If you’ve been hanging around 3D printing communities, or reading the various 3D printing posts that have popped up here on Hackaday, you’ve almost certainly heard of OctoPrint. Created and maintained by Gina Häußge, OctoPrint allows you to turn an old computer (or more commonly a small ARM board like the Raspberry Pi or BeagleBone) into a network-accessible control panel for your 3D printer. Thanks to a thriving collection of community developed plugins, it can even control other hardware such as lights, enclosure heaters, smart plugs, or anything else you can think to hook onto the GPIO pins of your chosen ARM board. The project has become so popular that the new Prusa i3 MK3 has a header on the control board specifically for connecting a Pi Zero W running OctoPrint.

Even still, I never personally “got” OctoPrint. I was happy enough with my single printer connected to my computer and controlled directly from my slicer over USB. The majority of the things I print are of my own design, so when setting up the printer it only seemed logical that I would have it connected to the machine I’d be doing my designing on. If I’m sitting at my computer, I just need to rotate my chair to the right and I’m at my printer. What do I need to control the thing over WiFi for?

But things got tricky when I wanted to set up a second printer to help with speeding up larger projects. I couldn’t control them both from the same machine, and while I could print from SD on the second printer if I really had to, the idea seemed painfully antiquated. It would be like when Scotty tried talking into the computer’s mouse in “Voyage Home”. Whether I “got it” or not, I was about to dive headfirst into the world of OctoPrint.

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When A Skimmer Isn’t A Skimmer

January 2, 2018 by Tom Nardi 163 Comments

I have a confession to make: ever since the first time I read about them online, I’ve been desperate to find an ATM skimmer in the wild. It’s the same kind of morbid curiosity that keeps us from turning away from a car accident, you don’t want to be witness to anyone getting hurt, but there’s still that desire to see the potential for danger up close. While admittedly my interest is largely selfish (I already know on which shelf I would display it), there would still be tangible benefits to the community should an ATM skimmer cross my path. Obviously I would remove it from the machine and prevent others from falling prey to it, and the inevitable teardown would make interesting content for the good readers of Hackaday. It’s a win for everyone, surely fate should be on my side in this quest.

So when my fingers brushed against that unmistakable knobby feel of 3D printed plastic as I went to insert my card at a local ATM, my heart skipped a beat. After all these years, my dream had come true. Nobody should ever be so excited about potentially being a victim of fraud, but there I was, grinning like an idiot in the farmer’s market. Like any hunter I quickly snapped a picture of my quarry for posterity, and then attempted to free it from the host machine.

But things did not go as expected. I spend most of my free time writing blog posts for Hackaday, so it’s safe to say that physical strength is not an attribute I possess in great quantity, but even still it seemed odd I couldn’t get the skimmer detached. I yanked it in every direction, tried to spin it, did everything short of kicking it; but absolutely no movement. In fact, I noticed that when pulling on the skimmer the whole face plate of the ATM bulged out a bit. I realized this thing wasn’t just glued onto the machine, it must have actually been installed inside of it.

I was heartbroken to leave my prize behind, but at the very least I would be able to alert the responsible party. The contact info for the ATM’s owner was written on the machine, so I emailed them the picture as well as all the relevant information in hopes that they could come check the machine out before anyone got ripped off.

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Try This For 3D Printing Without Support

December 29, 2017 by Al Williams 46 Comments

Have a look at the object to the right. Using a conventional fused deposition printer, how would you print the object? There’s no flat surface to lay on the bed without generating a lot of overhangs. That usually requires support.

In theory, you might be able to print the bottom of the sphere down, but it is difficult to get that little spot to adhere to the bed. If you have at least two extruders and you are set up to print support material, that might even be the best option. However, printing support out of the same material you are printing with makes it hard to get a good clean print. There is another possibility. It does require some post-processing, but then again, not as much as hacking away a bunch of support material.

A Simple Idea

The idea is simple and — at first — it will sound like a lot of trouble. The basic idea is to cut the model in half at some point where both halves would be easy to print and then glue them together. Stick around (no pun intended), though, because I’ll show you a way to make the alignment of the parts almost painless no matter how complex the object might be.

The practical problem with gluing together half models is getting the pieces in the exact position, but that turns out to be easy if you just make a few simple changes to your model. Another lesser problem is clamping a piece while gluing. You can use a vise, but some oddly-shaped parts are not conducive to traditional vise jaws.

In Practice

Starting with an OpenSCAD object, it is easy to cut the model in half. Actually, you could cut it anywhere. Then it is easy to rotate half of it so the cut line is at the bottom of each part. That doesn’t solve the alignment problem nor does it help you clamp when you glue.

The trick is to build a flange around each part. The flanges mate with a few screws after printing so alignment is perfect and bolts through the flange holes can keep the parts together and immobilized while your glue of choice sets. The kicker is that I even have an automated process to make the design side of this trick very easy.

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Hunting Rogue Access Points With The ESP8266

December 28, 2017 by Sean Boyce 32 Comments

Cantennas outperform every consumer-grade Wi-Fi antenna I’ve had the bad luck of purchasing. Cantenna is a mashup of ‘can’ and ‘antenna’ creating the nickname for a directional waveguide antenna built from re-purposed steel cans. For anyone who has yet to build one, it makes an excellent afternoon project. Here are some build instructions and technical details. I went beyond that, and ended up catching a rogue WiFi access point in the process.

When I needed to extend the range of some ESP8266-based sensors, cantennas were right at the top of my list of things to try. It was easy enough to build one, attach it to a Wemos Mini D1 Pro, and call the job done… leaving me with plenty of time to over-engineer it, and I ended up down a bit of a rabbit hole.

The first thing I did was stop using cans. Canned goods are not only expensive in my corner of the world, but more importantly don’t lend themselves that well to making a standardized antenna in volume. I can also only eat so many beans! The latter reason alone is enough to consider an alternative design like a modular dish reflector.

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34C3: The First Day Is A Doozy

December 27, 2017 by Elliot Williams 8 Comments

It’s 5 pm, the sun is slowly setting on the Leipzig conference center, and although we’re only halfway through the first day, there’s a ton that you should see. We’ll report some more on the culture of the con later — for now here’s just the hacks. Continue reading “34C3: The First Day Is A Doozy” →

2017: As The Hardware World Turns

December 27, 2017 by Brian Benchoff 28 Comments

The year is almost over, and now it’s time to look back on the last fifty-odd weeks. What happened in this year in hacking? 2017 will go down as the beginning of another AI renaissance, although we’re not going to call it that; this year was all about neural nets and machine learning and advancements resulting from the development of self-driving cars and very beefy GPUs. Not since the 80s have we seen more work in ‘AI’ fields. What will it amount to this time around the hype cycle? Find out in a few years.

Biohacking was big this year, and not just because people are installing RFID tags and magnets in their hands. CRISPR is allowing for Star Trek-style genome hacking, and this year saw in vivo experiments to enable and disable individual genes in rat models. Eventually, someone is going to get a Nobel for CRISPR.

We’re going to Mars, and soon — very soon — a SpaceX Falcon Heavy is going to either lob a Tesla Roadster into solar orbit or the Atlantic Ocean. We learned about the BFR that will take dozens of people to Mars in a single launch. Boeing and Lockheed think they can compete with the Elon Musk PR powerhouse. The Bigelow Aerospace inflatable module passed its in-flight test on the ISS, giving the space station a new storage closet. Even in space, amazing stuff is happening this year.

Is that it? Not by a long shot. This year has seen some of the coolest hacks we’ve ever seen, and some of the dumbest security breaches ever. Hackaday is doing awesome. What else did 2017 have? Read on to find out.

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