Halfway Between Inspiration And Engineering

We see a lot of hacks where the path to success is pretty obvious, if maybe strewn with all sorts of complications, land-mines, and time-sinks. Then we get other hacks that are just totally out-of-the-box. Maybe the work itself isn’t so impressive, or even “correct” by engineering standards, but the inner idea that’s so crazy it just might work shines through.

This week, for instance, we saw an adaptive backlight LED TV modification that no engineer would ever design. Whether it was just the easiest way out, or used up parts on hand, [Mousa] cracked the problem of assigning brightnesses to the LED backlights by taking a tiny screen, playing the same movie on it, pointing it at an array of light sensors, and driving the LEDs inside his big TV off of that. No image processing, no computation, just light hitting LDRs. It’s mad, and it involves many, many wires, but it gets the job done.

Similarly, we saw an answer to the wet-3D-filament problem that’s as simple as it could possibly be: basically a tube with heated, dry air running through it that the filament must pass through on it’s way to the hot end. We’ve seen plenty of engineered solutions to damp filament, ranging from an ounce of prevention in the form of various desiccant storage options, to a pound of cure – putting the spools in the oven to bake out. We’re sure that drying filament inline isn’t the right way to do it, but we’re glad to see it work. The idea is there when you need it.

Not that there’s anything wrong with the engineering mindset. Quite the contrary: most often taking things one reasonable step at a time, quantifying up all the unknowns, and thinking through the path of least resistance gets you to the finish line of your project faster. But we still have to admire the off-the-wall hacks, where the way that makes the most sense isn’t always the most beautiful way to go. It’s a good week on Hackaday when we get both types of projects in even doses.

Hackaday Podcast Episode 278: DIY Subs, The ErgoRing, And Finding NEMA 17

In this episode, Hackaday Editors Elliot Williams and Tom Nardi kick things off with a reminder about the impending deadline for Supercon talk and workshop proposals. From there discussion moves on to the absolutely incredible tale of two brothers who solved a pair of missing person cases with their homebrew underwater vehicle, false data sneaking into OctoPrint’s usage statics, and an organic input device that could give the classic mouse a run for its money.

You’ll also hear about cheap radar modules, open source Xbox mod chips, and lawnmowers from the grocery store. The episode wraps up with a look at the enduring mystique of perpetual motion devices, and the story of a legendary ship that might soon end up being turned into paper clips.

Check out the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

As always, this week’s episode is available as a DRM-free MP3.

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This Week In Security: Hide Yo SSH, Polyfill, And Packing It Up

The big news this week was that OpenSSH has an unauthorized Remote Code Execution exploit. Or more precisely, it had one that was fixed in 2006, that was unintentionally re-introduced in version 8.5p1 from 2021. The flaw is a signal handler race condition, where async-unsafe code gets called from within the SIGALARM handler. What does that mean?
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FLOSS Weekly Episode 790: Better Bash Scripting With Amber

This week Jonathan Bennett and Dan Lynch chat with Paweł Karaś about Amber, a modern scripting language that compiles into a Bash script. Want to write scripts with built-in error handling, or prefer strongly typed languages? Amber may be for you!

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USB And The Myth Of 500 Milliamps

If you’re designing a universal port, you will be expected to provide power. This was a lesson learned in the times of LPT and COM ports, where factory-made peripherals and DIY boards alike had to pull peculiar tricks to get a few milliamps, often tapping data lines. Do it wrong, and a port will burn up – in the best case, it’ll be your port, in worst case, ports of a number of your customers.

Want a single-cable device on a COM port? You might end up doing something like this.

Having a dedicated power rail on your connector simply solves this problem. We might’ve never gotten DB-11 and DB-27, but we did eventually get USB, with one of its four pins dedicated to a 5 V power rail. I vividly remember seeing my first USB port, on the side of a Thinkpad 390E that my dad bought in 2000s – I was eight years old at the time. It was merely USB 1.0, and yet, while I never got to properly make use of that port, it definitely marked the beginning of my USB adventures.

About six years later, I was sitting at my desk, trying to build a USB docking station for my EEE PC, as I was hoping, with tons of peripherals inside. Shorting out the USB port due to faulty connections or too many devices connected at once was a regular occurrence; thankfully, the laptop persevered as much as I did. Trying to do some research, one thing I kept stumbling upon was the 500 mA limit. That didn’t really help, since none of the devices I used even attempted to indicate their power consumption on the package – you would get a USB hub saying “100 mA” or a mouse saying “500 mA” with nary an elaboration.

Fifteen more years have passed, and I am here, having gone through hundreds of laptop schematics, investigated and learned from design decisions, harvested laptops for both parts and even ICs on their motherboards, designed and built laptop mods, nowadays I’m even designing my own laptop motherboards! If you ever read about the 500 mA limit and thought of it as a constraint for your project, worry not – it’s not as cut and dried as the specification might have you believe.
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Retrotechtacular: The Tools And Dies That Made Mass Production Possible

Here at Hackaday we’re suckers for vintage promotional movies, and we’ve brought you quite a few over the years. Their boundless optimism and confidence in whatever product they are advancing is infectious, even though from time to time with hindsight we know that to have been misplaced.

For once though the subject of today’s film isn’t something problematic, instead it’s a thing we still rely on today. Precision manufacturing of almost anything still relies on precision tooling, and the National Tool and Die Manufacturers Association is on hand in the video from 1953 below the break to remind us of the importance of their work.

The products on show all belie the era in which the film was made: a metal desk fan, CRT parts for TVs, car body parts, a flight of what we tentatively identify as Lockheed P-80 Shooting Stars, and a Patton tank. Perhaps for the Hackaday reader the interest increases though when we see the training of an apprentice toolmaker, a young man who is being trained to the highest standards in the use of machine tools. It’s a complaint we’ve heard from some of our industry contacts that it’s rare now to find skills at this level, but we’d be interested to hear views in the comments on the veracity of that claim, or whether in a world of CAD and CNC such a level of skill is still necessary. Either way we’re sure that the insistence on metrology would be just as familiar in a modern machine shop.

A quick web search finds that the National Tool and Die Manufacturers Association no longer exists, instead the search engine recommends the National Tooling And Machining Association. We’re not sure whether this is a successor organisation or a different one, but it definitely represents the same constituency. When the film was made, America was at the peak of its post-war boom, and the apprentice would no doubt have gone on to a successful and pretty lucrative career. We hope his present-day equivalent is as valued.

If you’re of a mind for more industrial process, can we direct you at die casting?

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Illustrated Kristina with an IBM Model M keyboard floating between her hands.

Keebin’ With Kristina: The One With The Tasty Snacks Board

A pocket cyberdeck-looking thing with a screen and a thumb keyboard.
Image by [MakerM0] via Hackaday.IO
[MakerM0]’s LangCard is an entry into our 2024 Business Card Challenge that just so happens to fit the Keebin’ bill as well.

You might label this a pocket cyberdeck, and that’s just fine with me. The idea here is to have a full-keyboard development board for learning programming languages like CircuitPython, MicroPython, C++, and so on, wherever [MakerM0] happens to be at a given moment.

Open up the LangCard and you’ll find an RP2040 and a slim LiPo battery. I’m not sure what display that is, but there are probably a few that would work just fine were you to make one of these fun learning devices for yourself.

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