Design For Hackers

July 27, 2016 by Elliot Williams 53 Comments

Near the end of the lifecycle of mass-market commercial product development, an engineering team may come in and make a design for manufacturability (DFM) pass. The goal is to make the device easy, cheap, and reliable to build and actually improve reliability at the same time. We hackers don’t usually take this last step, because when you’re producing just a couple of any given device, it hardly makes sense. But when you release an open-source hardware design to the world, if a lot of people re-build your widget, it might be worth it to consider DFM, or at least a hardware hacker’s version of DFM.

If you want people to make their own versions of your project, make it easy and cheap for them to do so and don’t forget to also make it hackable. This isn’t the same as industrial DFM: rather than designing for 100,000s of boards to be put together by robot assembly machines, you are designing for an audience of penny-pinching hackers, each building your project only once. But thinking about how buildable your design is will still be worthwhile.

In this article, I’m going to touch on a couple of Design for Hackers (DFH) best practices. I really want to hear your experience and desires in the comments. What would you like to see in someone else’s open designs? What drives you nuts when replicating a project? What tricks do you know to make a project easily and cheaply buildable by the average hacker?

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History Of The Capacitor – The Modern Era

July 26, 2016 by Steven Dufresne 20 Comments

The pioneering years in the history of capacitors was a time when capacitors were used primarily for gaining an early understanding of electricity, predating the discovery even of the electron. It was also a time for doing parlor demonstrations, such as having a line of people holding hands and discharging a capacitor through them. The modern era of capacitors begins in the late 1800s with the dawning of the age of the practical application of electricity, requiring reliable capacitors with specific properties.

Leyden Jars

Marconi with transmitting apparatus, Published on LIFE [Public domain], via Wikimedia Commons

One such practical use was in Marconi’s wireless spark-gap transmitters starting just before 1900 and into the first and second decade. The transmitters built up a high voltage for discharging across a spark gap and so used porcelain capacitors to withstand that voltage. High frequency was also required. These were basically Leyden jars and to get the required capacitances took a lot of space.

Mica

In 1909, William Dubilier invented smaller mica capacitors which were then used on the receiving side for the resonant circuits in wireless hardware.

Early mica capacitors were basically layers of mica and copper foils clamped together as what were called “clamped mica capacitors”. These capacitors weren’t very reliable though. Being just mica sheets pressed against metal foils, there were air gaps between the mica and foils. Those gap allowed for oxidation and corrosion, and meant that the distance between plates was subject to change, altering the capacitance.

In the 1920s silver mica capacitors were developed, ones where the mica is coated on both sides with the metal, eliminating the air gaps. With a thin metal coating instead of thicker foils, the capacitors could also be made smaller. These were very reliable. Of course we didn’t stop there. The modern era of capacitors has been marked by one breakthrough after another for a fascinating story. Let’s take a look.

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What It’s Like To Quit Your Job And Start A Company – Then Fail

July 25, 2016 by Cameron Coward 142 Comments

Some of our more dedicated readers may remember me as that promising and talented new writer who disappeared after only a couple of months last fall. Or, alternatively, that moronic new writer who had no idea what he was talking about. But, I’m just going to go ahead and assume it was the former in order to protect my ego. In either case, if you remember me at all, you may have wondered why I left. Was it cholera? Was I drafted into a top-secret CIA program? Did I join a circus as a fledgling trapeze artist?

No, it was none of that. That would be absurd. What would make you think I had any trapeze skills at all, much less circus-worthy ones? The truth is a lot more straightforward, but was also a lot scarier (and more exciting) for me — I started a business. The astute readers among you have probably already put the dots together and figured out that I failed. The title was a pretty strong hint, right? This isn’t a story of bootstraps-pulling success, or a heartwarming underdog tale. This is an opportunity for me to talk about the lessons I learned as I failed, and to give the entrepreneurs out there something to consider when they start their businesses. We’ll laugh together, we’ll cry together, and maybe we’ll even learn something together. Ready? Alright, let’s dive right into the heart of it, starting when I was seven years old…

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MicroPython On The ESP8266: Kicking The Tires

July 21, 2016 by Elliot Williams 32 Comments

Scripting languages are for large computers, right? “Real” embedded device work is a hellish, never-ending cycle of code, compile, and re-flash. Well, I used to think so too, but with the proliferation of scripting and other interactive languages to microcontrollers over the last few years, the hurdle to interactive development on the small chips has gotten a lot lower.

On the ESP8266 platform, I’ve tried out NodeMCU’s Lua and ESP8266 BASIC. (For the last half-year, I’ve been using the awesome Mecrisp-Stellaris almost exclusively on the STM32F1xx and F4xx chips, but haven’t dipped into ESP8266 Forth yet.)

NodeMCU is great because it’s got everything you could want built in, and through cloud services it’s easy to get a tailored build made that maximizes free flash memory for your projects. I just don’t dig the asynchronous Lua thing (you might, try it!). ESP BASIC has a different set of libraries, and is missing MQTT for my purposes. Still it’s pretty slick, and worth a look.

So when the MicroPython folks announced that they were releasing the binary builds for the ESP, I thought it was time to give it a spin. I’ve used Python for nearly twelve years now, so it’s like a comfortable shoe for me. Would MicroPython be the same on the ESP8266? The short answer is yes and no.

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Hackaday SuperConference: Call For Proposals

July 19, 2016 by Mike Szczys 1 Comment

The 2016 Hackaday SuperConference is coming. Now is the time to submit your proposal for a talk or a workshop at the world’s greatest conference about hardware creation. The SuperCon is an unparalleled opportunity to present on a deeply technical level where you can be certain everyone in the audience is following. All of those details, the war stories of production, the out-of-stock problems and board respins, the moments when you’ve bent physics to your will, these stories will be met with awe and cheers as the audience of your peers takes the ride along with you.

SuperCon will take place in Pasadena, California on November 5th and 6th, 2016. It is a gathering of hackers, designers, and engineers passionate about learning, teaching, and celebrating what goes into making new and exciting creations. The atmosphere will be that of a hacker village, with several venues in close proximity playing host to talks, workshops, and other activities. This breaks out of the beige prison that usually accompanies hotel-based conferences and opens the weekend up for you to meet and interact with a cadre of interesting people. SuperCon is the place to share your hard-won knowledge and experience, and to add to your own arsenal of skills.

Accepted talks will be scheduled for 20-40 minutes, and workshops will be booked for 1-4 hours. In both cases, topics may include themes like techniques for rapid prototyping, new and interesting uses of technology, creativity in technical design, and stories of product development and manufacturing.

Last year’s SuperConference was incredibly successful. If you weren’t able to attend you can still work your way through all of the talks which were recorded and posted shortly after the event. That success is a credit to all of the talented presenters in the Hackaday community who put together their stories to share for the benefit of all. Thank you!

To all of you reading this now and wondering if you should propose a talk, you should! We thank you in advance for taking time out of your life to make this year’s SuperConference even more amazing by submitting your own proposal. It won’t happen without you because this is a conference of active involvement and not one of passive consumption. Be the hardware movement; this is your chance.

Hackerspaces Are Hard: Insurance

July 19, 2016 by Kristina Panos 48 Comments

Do you dream of opening a hackerspace, makerspace, or co-working space? Maybe it’s in the works and you’re already scoping out locations, intoxicated by visions of all the projects that will emerge from it. Here’s a sobering thought: makerspaces are a great big pile of risk. If the doors of your ‘space are already open, perhaps you’ve come to realize that the initial insurance policy you signed doesn’t really fit the needs of your particular creative paradise. Even if it does, the protection you need will change as you acquire new toys.

So why should you even get insurance? For one thing, your landlord will probably require it. If you own the building, you should insure it to protect yourself and anyone who uses the space. Do it for the same reason you’d insure a car, your house, or your collection of vintage pinball machines: to mitigate risk. It takes a lot of hard work to open a makerspace, perform the day-to-day operations, and keep it growing and getting better. Whenever the unthinkable happens, insurance will protect your investment as well as the people who make it a great place to be.

In researching this article, I contacted several well-established makerspaces in the United States as well as most of the major insurance providers to get both sides of the story. My intent was not to make a how-to guide, but to simply explore the topic and provide a view of the process and the struggle.

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Sonic 3D Printer Auto Bed Leveling Makes A Swoosh

July 18, 2016 by Moritz Walter 49 Comments

3D Printering: the final frontier. These are the voyages of another 3D printer hack. Its mission: to explore strange new ways of leveling a print bed.

So far, we’ve had servo probes, Allen key probes, Z-sled probes, inductive and capacitive contactless switches, just to name a few. All of them allow a 3D printer to probe its print bed, calculate a correction plane or mesh, and compensate for its own inherent, time variant, inaccuracies.

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