hardware

1667 Articles

Organizing Components, The Easy Way

January 3, 2025 by 50 Comments

There’s an old joke: What do you get someone who has everything? A place to put it. For hackers like [Christian], everything is a hoard of priceless electronic components. His solution is using small zipper bags, either regular plastic or anti-static. These attach using hook and loop fastener to plastic binder sheets which then live in a binder. Combined with some custom printed labels and a few other tricks, it makes for a nice system, as you can see in the video below.

Honestly, we’ve done something similar before, using a binder with little pockets, but the bag and custom labels beat our system. He even has QR codes on some of them to locate data sheets easily. Seems like a barcode for inventory management might have been good, too.

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Ball Nut Modification Charts A Middle Course Between Building And Buying

December 29, 2024 by 7 Comments

A lot of the projects we feature here on Hackaday engender the classic “build versus buy” argument. We’ve always been puzzled by that; if anyone can appreciate the sheer joy of making something rather than buying it, it should be our readers. But there’s something to be said for buying the stuff you can buy and concentrating your effort on the bespoke aspects of the project. It’s perhaps not as exciting, but needs must, oftentimes.

Let’s not forget there’s a third way though, which [Andy] explores with this ball nut modification project. Keen-eyed readers will recall [Andy]’s recent scratch-built ball screw build, in service of some top-secret, hush-hush project related to world domination and total subjugation of humanity. His homebrew efforts in this regard were a great lesson in how to machine a complex mechanism to work in a constrained space. Still, it left folks wondering why he’d go to all the trouble when he could have just trimmed an off-the-shelf part down to size. So, he decided to give that a try.

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Programmable Zener Is Really An IC

November 24, 2024 by 25 Comments

[Kevin] doesn’t stock zener diodes anymore. Why? Because for everything he used to use zeners, he now uses TL431 bandgap voltage references. These look like zener diodes but have an extra terminal. That extra terminal allows you to set the threshold to any value you want (within specifications, of course). Have a look at the video below for an introduction to these devices and a practical circuit on a breadboard.

Inside, there’s a voltage reference, an op-amp, and a transistor, so these are tiny 3-terminal ICs. The chip powers itself from the load, so there are no separate power supply pins.

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Large gears on a bridge in Geneva, Switzerland

Gear Up: A 15-Minute Intro On Involute Gears

November 21, 2024 by 10 Comments

If you’re into CNC machining, mechanical tinkering, or just love a good engineering rabbit hole, you’re in for a treat. Substack’s [lcamtuf] has written a quick yet insightful 15-minute introduction to involute gears that’s as informative as it is accessible. You can find the full article here. Compared to Hackaday’s more in-depth exploration in their Mechanisms series over the years, this piece is a beginner-friendly gateway into the fascinating world of gear design.

Involute gears aren’t just pretty spirals. Their unique geometry minimizes friction and vibration, keeps rotational speeds steady, and ensures smooth torque transfer—no snags, no skips. As [lcamtuf] points out, the secret sauce lies in their design, which can’t be eyeballed. By simulating the meshing process between a gear and a rack (think infinite gear), you can create the smooth, rolling movement we take for granted in everything from cars to coffee grinders.

From pressure angles to undercutting woes, [lcamtuf] explores why small design tweaks matter. The pièce de résistance? Profile-shifted gears—a genius hack for stronger teeth in low-tooth-count designs.

Whether you’re into the theory behind gear ratios, or in need of a nifty tool to cut them at home, Hackaday has got you covered. Inspired?

USB-C For Hackers: Reusing Cables

November 21, 2024 by 82 Comments

Your project needs a cable, and since USB-C cables are omnipresent now, it’s only natural to want to reuse them for your evil schemes. Ever seen USB 3.0 cables used for PCIe link carrying duty? It’s because USB 3.0 cables are built to a reasonably high standard, both sockets and cables are easy to find, and they’re cheap. Well, USB-C cables beat USB 3.0 cables by all possible metrics.

Let’s go through USB-C cable reuse in great detail, and see just what exactly you get when you buy either a gas station C-C USB 2.0 cable, or, the fanciest all-features-supported 240 W Thunderbolt cable that money can buy. Looking for a cable to cut, or something to pass a seriously high-speed link? You’re reading the right article.

The Omnipresent Cables

USB-A to USB-C cables are the least interesting. They’re equivalent to a microUSB to USB-A cable, except there’s a resistor on the USB-C plug, connected from VBUS to one of the CC pins. That’s it. The cable contains four conductors, there’s really not much new. Save these cables for all the devices still built without the 5.1 kΩ resistors.

Now, a USB-C to USB-C cable – let’s say, 60 W max, the default USB-C cable capability. If your cable says anything less than 60 W, say, “2 A” or “15 W”, that’s a lie – it can handle 60 W no problem, all USB-C to C cables can do 60 W. This cable is also cool – for one, it has five conductors; GND, VBUS, D+, D-, and CC. Two of them (GND and VBUS) are guaranteed to be thick enough to carry 3 A without much voltage drop if any, too!

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ESP32 Hosts A USB Keyboard In This Typewriter

November 17, 2024 by 14 Comments

Did you know the ESP32 can be a USB host? Well it can, and [Volos] uses host mode to build this fun little word processor.

The venerable ESP32 has a well-known USB device mode. Anyone who has programmed one has used it. A bit less known is the microcontroller’s ability to host USB devices. These days, operating as a USB device is relatively simple. But acting as a host is a much more complex task. The ESP32 has a software host that works — but only for Human Interface Devices (HID).  Human interface devices generally are keyboards, mice, trackballs, and similar devices that handle data relatively slowly, forming the interface with us simple humans.

[Volos] uses the EspUsbHost Arduino library for this project. The library makes USB host mode simple to use. Another piece of the puzzle is the LCD board [Volos] picked. It has a dual-role USB Type-C port, meaning the hardware to switch roles is baked in. Other boards may require some modifications or special cables to make things work.

The software is the best part of this build. [Volos] implemented a simple word processor. It can save and load files from a microSD card and, of course, edit text — all controlled by a USB keyboard. He had to use a 4-bit palette to save memory. This gives the device a retro charm that reminds us of Don Lancaster’s TV Typewriter. The source for this and all of [Volos] projects can be found on GitHub. Now, all we need is a spell check that can fit in the memory constraints of the ESP32! We have to admit the chip has a lot of potential USB tricks.

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Ethernet From First Principles

November 16, 2024 by 24 Comments

For someone programming in a high-level language like Python, or even for people who interact primarily with their operating system and the software running on it, it can seem like the computer hardware is largely divorced from the work. Yes, the computer has to be physically present to do something like write a Hackaday article, but most of us will not understand the Assembly language, machine code, or transistor layout well enough to build up to what makes a browser run. [Francis Stokes] is a different breed, though, continually probing these mysterious low-level regions of our computerized world where he was recently able to send an Ethernet packet from scratch.

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