a flexible film with a matrix of illuminated color LEDs being stretched

Truly Flexible Circuits Are A Bit Of A Stretch

April 3, 2023 by Michael Shaub 5 Comments

Flexible PCBs have become increasingly common in both commercial devices and DIY projects, but Panasonic’s new stretchable, clear substrate for electrical circuits called Beyolex takes things a step further. The material is superior to existing stretchable films like silicone, TPU, or PDMS due to its high heat tolerance (over 160° C) for the purposes of sintering printable circuit traces.

But, a flexible substrate isn’t very useful for electronics without some conductive traces. Copper and silver inks make for good electrical circuits on stretchable films, and are even solderable, but increase resistance each time they are stretched. Recently, a team out of the University of Coimbra in Portugal has developed a liquid metal ink that can stretch without the resistance issues of existing inks, making it a promising pair with Panasonic’s substrate. There’s also certain environmental benefits of printing circuits in this manner over traditional etching and even milling, as you’re only putting conductive materials where needed.

After the break, check out Panasonic’s earlier videos showing some of their demo circuits that include a stretchable NFC antenna harvesting electricity even while submerged in water and an LED matrix performing while being, bent, rolled, and stretched. We’re excited to see where this technology leads and when we hackers will be able to create our own stretchable projects.

A great many flexible PCB projects have graced Hackaday, from early experiments to sophisticated flexible PCB projects. Heck, we had a whole Flexible PCB Contest with some awesome flexible projects.

Continue reading “Truly Flexible Circuits Are A Bit Of A Stretch” →

PCIe For Hackers: Extracting The Most

March 30, 2023 by Arya Voronova 25 Comments

So, you now know the basics of approaching PCIe, and perhaps you have a PCIe-related goal in mind. Maybe you want to equip a single-board computer of yours with a bunch of cheap yet powerful PCIe WiFi cards for wardriving, perhaps add a second NVMe SSD to your laptop instead of that Ethernet controller you never use, or maybe, add a full-size GPU to your Raspberry Pi 4 through a nifty adapter. Whatever you want to do – let’s make sure there isn’t an area of PCIe that you aren’t familiar of.

Splitting A PCIe Port

You might have heard the term “bifurcation” if you’ve been around PCIe, especially in mining or PC tinkering communities. This is splitting a PCIe slot into multiple PCIe links, and as you can imagine, it’s quite tasty of a feature for hackers; you don’t need any extra hardware, really, all you need is to add a buffer for REFCLK. See, it’s still needed by every single extra port you get – but you can’t physically just pull the same clock diffpair to all the slots at once, since that will result in stubs and, consequently, signal reflections; a REFCLK buffer chip takes the clock from the host and produces a number of identical copies of the REFCLK signal that you then pull standalone. You might have seen x16 to four NVMe slot cards online – invariably, somewhere in the corner of the card, you can spot the REFCLK buffer chip. In a perfect scenario, this is all you need to get more PCIe out of your PCIe.

Continue reading “PCIe For Hackers: Extracting The Most” →

PCIe For Hackers: Link Anatomy

March 23, 2023 by Arya Voronova 17 Comments

Last time, we looked over diffpairs, their basics, routing rules and the notorious tolerances of PCIe when it comes to diffpairs. Now, let’s take a look at the exact signals that make PCIe tick, as well as give you an overview of which sockets you can get PCIe on.

I separate PCIe sockets into two categories – desktop sockets, which are the usual 1x, 16x, or perhaps x4 PCIe sockets we see on desktop motherboards — and mobile sockets: mPCIe and M.2. There are also sockets like ExpressCard that are still found on some older laptops, but they have definitely fallen out of relevance. On mobile, M.2 is the way forward when it comes to PCIe – if you’re interested, I’ve written a short series talking about everything M.2 before.

On these sockets, most signals will be optional and some signals will be socket-specific, but there are some signals required in any PCIe device. Of course, the first group of required signals is the PCIe diffpairs themselves.

Continue reading “PCIe For Hackers: Link Anatomy” →

Dispense 60 Bolts In 2.3 Seconds

March 21, 2023 by Michael Shaub 26 Comments

We’ve covered a number of projects that assist makers who need to fill orders for their small businesses, or kitting. [Helmke] has sorted thousands of pieces of hardware that they include with 3D printed parts sold online. They have been developing an alternative, a modular system for sorting and packaging specific quantities of parts.

After the break, check out the latest video from their small but growing channel for a very clear walk-through of the counting system they’ve been iterating on. The 2nd video in the series explores solenoids, Geneva drives, and ultimately a sprocket to dispense a variable number of bolts from the sorting machine. The approach gives consistent results, easily to vary quantities, and is fast! These videos are also rich with lots of small details you might want to explore on your own like magnetic part feeding, discussions of different sensors for detecting and counting parts, 3D printed gear box designs, and we love the use of stackable crates for project enclosures.

We hope to see more videos from [Helmke] in the series as the project matures for deeper dives into the existing mechanisms and new features they develop next. Hungry for more? We’ve brought you everything from cutting and stripping wire, to SMD tape, to resistors, to laser-cut parts. Continue reading “Dispense 60 Bolts In 2.3 Seconds” →

Sixteen wires of various colors are attached in pairs to record the electrical activity of split gill fungi (Schizophyllum commune) on a mossy, wooden stick. photo by Irina Petrova Adamatzky

Unconventional Computing Laboratory Grows Its Own Electronics

March 15, 2023 by Navarre Bartz 6 Comments

While some might say we’re living in a cyberpunk future already, one technology that’s conspicuously absent is wetware. The Unconventional Computing Laboratory is working to change that.

Previous work with slime molds has shown useful for spatial and network optimization, but mycelial networks add the feature of electrical spikes similar to those found in neurons, opening up the possibility of digital computing applications. While the work is still in its early stages, the researchers have already shown how to create logic gates with these fantastic fungi.

Long-term, lead researcher [Andrew Adamatzky] says, “We can say I’m planning to make a brain from mushrooms.” That goal is quite awhile away, but using wetware to build low power, self-repairing fungi devices of lower complexity seems like it might not be too far away. We think this might be applicable to environmental sensing applications since biological systems are likely to be sensitive to many of the same contaminants we humans care about.

We’ve seen a other efforts in myceliotronics, including biodegradable PCB substrates and attempts to send sensor signals through a mycelial network.

Via Tom’s Hardware.

Photograph of a BLDC motor controller circuit board

Take A Ride Through The Development Of A Custom BLDC Motor Controller

March 15, 2023 by Abe Connelly 6 Comments

The folks over at the [Barkhausen Institut] are doing research into controlling autonomous fleets of RC cars and had been using off the shelf electronic speed controllers (ESCs) to control the car motors. Unfortunately they required more reliable feedback for closed loop control of the motors, so they created their own open source hardware brushless DC (BLDC) controller.

The motor controller they developed uses an STM32 microcontroller that talks to a TMC6140 3 phase MOSFET driver to drive 6 IRLR 2905 MOSFETs. The [Barkhausen Institut] researchers went with the SimpleFOC library as the basis to program the STM32, with installed hall effect sensors indicating motor orientation for their closed loop control.

Designing a functioning BLDC and ESC controllers can be subtle, and their post goes into details about the problems and solutions they came up with to deal with with what was ultimately improper isolation of the MOSFETs interfering with the power rail for the STM32. The source for their BLDC motor controller is available through their GitLab page. For more information on the parent project that uses the BLDC driver, be sure to check out their work on a connected convoy of RC cars.

There’s now a wealth of open source BLDC drivers and projects, many of which we’ve featured in the past, like the Moteus and haptic smart knob, and it’s nice to see other projects explore different options.

PCIe For Hackers: The Diffpair Prelude

March 14, 2023 by Arya Voronova 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” →