CCA Ethernet Cables: Not Up To Scratch, But Are They Dangerous?

April 7, 2026 by Zoe Skyforest 57 Comments

If you’ve ever bought a suspiciously cheap Ethernet cable from an online listing, there’s a decent chance you’ve encountered Copper Clad Aluminum. Better known as CCA, it’s exactly what it sounds like—an aluminium conductor with a thin skin of copper deposited on the outside. Externally, cables made with this material look largely like any other, with perhaps the only obvious tell being that they feel somewhat lighter in the hand.

CCA is cheaper than proper copper cabling, and it conducts signals well enough to function in an Ethernet cable. And yet, it’s a prime example of corner-cutting that keeps standards bodies and professional installers up at night. But just how dangerous is this silent scourge, found lurking in so many network cabinets around the world?

Not Up To Scratch

CCA wire is typically made by wrapping an aluminium core with copper strip and then extruding it through a die. Credit: USPTO

Everything you need to know about CCA is in the name—it refers to an aluminium wire with a thin copper cladding, typically applied through a die extrusion process. The reasoning behind this exploits a real physical phenomenon called the skin effect, wherein higher-frequency AC signals tend to travel along the outer surface of a conductor. The idea goes that since most of the current moves through the outer copper skin layer anyway, the less-conductive aluminium core doesn’t unduly impact the wire’s performance. Using copper-clad aluminium wiring is, in theory, desirable because aluminium is much cheaper than copper, which can really add up over long cable runs. Imagine you’re wiring a building with with hundreds of miles of Ethernet cabling, all with eight conductors each—the savings add up pretty quickly.

There’s a problem with CCA cabling in these contexts, though. Due to prevailing cabling standards, any cable made with CCA is technically not even a real Ethernet cable at all. The relevant documents are unambiguous.

ANSI/TIA-568.2-D requires conductors in Category-rated cable to be solid or stranded copper. No other materials are acceptable, and thus CCA is explicitly excluded from use in Category cable applications. A cable with CCA conductors cannot legitimately carry a Cat5e, Cat6, or any related designation under any circumstances. Similarly, ISO/IEC 11801 has the same requirement. The U.S. National Electrical Code also states that conductors in communications cables, other than coaxial cable, shall be copper. This isn’t a suggestion or a best practice; it’s the letter of the code. Anything lesser is simply not allowed. Continue reading “CCA Ethernet Cables: Not Up To Scratch, But Are They Dangerous?” →

In Space (Probably) Everyone Can Hear You.. Well, You Know

April 6, 2026 by Al Williams 28 Comments

The news is full of reports from the moon-bound Integrity, otherwise known as Artemis II. Mostly, the news is good, but there has been one “Houston, we have a problem…” moment. The space toilet, otherwise known as the Universal Waste Management System or UWMS is making a burning smell while in use. While we would love to be astronauts, we really don’t want to go ten days without using the can, and it made us wonder how, exactly, the astronauts answered the call of nature.

The Old Days

Back in the Apollo-era, going to the bathroom was a messy business. The capsule wasn’t that big, and there were no women on board. So you simply strapped an adhesive-rimmed bag or tube to yourself and answered nature’s call with your two closest coworkers right there.

Space Shuttle facilities (by [Svobodat] CC BY-SA 3.0)

To add insult to injury, the “#2 bags” needed some packet mixed in to keep it from going bad in the bag before it could return to Earth for — no kidding — scientific study.

The system was far from perfect. Apollo 8 and Apollo 10 both had to do some housekeeping due to leaky bags.

Astronaut Ken Mattingly reportedly said, “Man, one of the feats of my existence the other day was, in 42 minutes, I strapped on a bag, went out of both ends, and ate lunch…. I used to want to be the first man to Mars. This has convinced me that, if we got to go on Apollo, I ain’t interested.”

Still, it was better than the first Mercury launch, where Alan Shepard famously relieved himself in his spacesuit while sitting on the pad for over eight hours. Later missions used hoses.

Things got slightly better with Skylab, where there was more room. The Shuttle also had a toilet. You got a curtain for privacy, but you couldn’t go #1 and #2 at the same time. Also, apparently, the contraptions were not easily workable for females.

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With Affordable Storage Options Dwindling, Where To Store Our Data?

April 6, 2026 by Maya Posch 66 Comments

These days our appetite for more data storage is larger than ever, with video files larger, photo resolutions higher, and project files easily zipping past a few hundred MB. At the same time our options for data storage are becoming more and more limited. For the longest time we could count on there always being a newer, roomier, faster, and cheaper form of storage to come along, but those days would seem to be over.

We can look back and laugh at low capacity USB Flash drives of the early 2000s, yet the first storage drive to hit 1 TB capacity did so in 2007, with a Hitachi Deskstar 7k100, only for that level of capacity in PCs to not really be exceeded nineteen years later.

We also had Blu-ray discs (BD) promise to cram the equivalent of dozens of DVDs onto a single BD, with two- and even four-layer BDs storing up to a one-hundred-and-twenty-eight GB. Yet today optical media is dying a slow death as the sole remaining cheap storage option. NAND Flash storage has only increased in price, and the options for those of us who have large cold storage requirements would seem to be decreasing every day.

So what is the economical solution here? Invest in LTO tapes using commercial left-overs, or give up and sign up for Cloud Storage™ for the low-low price of a monthly recurring fee?

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Sega Meganet: Online Gaming In 1990

April 2, 2026 by Zoe Skyforest 20 Comments

It’s easy to think of online console gaming as an invention of the 2000s. Microsoft made waves when Xbox Live dropped in 2002, with Nintendo and Sony scrambling to catch up with their own offerings that were neither as sleek or well-integrated.

However, if you were around a decade earlier, you might have experienced online console gaming much closer to the dawn of the Internet era. As far back as 1990, you could jump online with your Sega Mega Drive. But what did an online console feel like in the dial-up era?

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Ask Hackaday: How Much Compute Is Enough?

April 2, 2026 by Tyler August 83 Comments

Over the history of this business, a lot of people have foreseen limits that look rather silly in hindsight– in 1943, IBM President Thomas Watson declared that “I think there is a world market for maybe five computers.” That was more than a little wrong. Depending on the definition of computers– particularly if you include microcontrollers, there’s probably trillions of the things.

We might as well include microcontrollers, considering how often we see projects replicating retrocomputers on them. The RP2350 can do a Mac 128k, and the ESP32-P4 gets you into the Quadra era. Which, honestly, covers the majority of daily tasks most people use computers for.

The RP2350 and ESP32-P4 both have more than 640kB of RAM, so that famous Bill Gates quote obviously didn’t age any better than Thomas Watson’s prediction. As Yogi Berra once said: predictions are hard, especially about the future. Continue reading “Ask Hackaday: How Much Compute Is Enough?” →

Ask Hackaday: Using CoPilot? Are You Entertained?

April 1, 2026 by Al Williams 55 Comments

There’s a great debate these days about what the current crop of AI chatbots should and shouldn’t do for you. We aren’t wise enough to know the answer, but we were interested in hearing what is, apparently, Microsoft’s take on it. Looking at their terms of service for Copilot, we read in the original bold:

Copilot is for entertainment purposes only. It can make mistakes, and it may not work as intended. Don’t rely on Copilot for important advice. Use Copilot at your own risk.

While that’s good advice, we are pretty sure we’ve seen people use LLMs, including Copilot, for decidedly non-entertaining tasks. But, at least for now, if you are using Copilot for non-entertainment purposes, you are violating the terms of service.

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Improving FDM Filament Drying With A Spot Of Vacuum

March 31, 2026 by Maya Posch 33 Comments

Keeping your filament safely away from moisture exposure is one of the most crucial aspects of getting a good 3D print, with equipment like a filament dryer a standard piece of equipment to help drive accumulated moisture out of filament prior to printing or storage. Generally such filament dryers use hot air to accomplish this task over the course of a few hours, but this is not very efficient for a number of reasons. Increasing the vaporization rate of water without significantly more power use should namely be quite straightforward.

The key here is the vapor pressure of a liquid, specifically the point at which it begins to transition between its liquid and gaseous phases, also known as the boiling point. This point is defined by both temperature and atmospheric pressure, with either factor being adjustable. In a pressure cooker this principle is for example used to increase the boiling temperature of water, while for our drying purposes we can instead reduce the pressure in order to lower the boiling point.

Although a lower pressure is naturally more effective, we can investigate the best balance between convenience and effectiveness.

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