You may have heard the phrase “flip-chip” before: it’s a broad term referring to several integrated circuit packaging methods, the common thread being that the semiconductor die is flipped upside down so the active surface is closest to the PCB. As opposed to the more traditional method in which the IC is face-up and connected to the packaging with bond wires, this allows for ultimate packaging efficiency and impressive performance gains. We hear a lot about advances in the integrated circuits themselves, but the packages that carry them and the issues they solve — and sometimes create — get less exposure.
Cutaway view of traditional wire-bond BGA package. Image CC-BY-SA 4.0 @TubeTimeUS
Let’s have a look at why semiconductor manufacturers decided to turn things on their head, and see how radioactive solder and ancient Roman shipwrecks fit in.
We often talk about the advantages of modular hardware here at Hackaday; the ability to just order a few parts online, hook them up with some jumper wires, and move onto the software side of things is a monumental time saver when it comes to prototyping. So anytime we see a new module that’s going to save us time and aggravation down the road, we get a bit excited.
Today we present the very slick I2CNavKey developed by [Saimon], a turn-key interface solution for your builds that can’t quite get away with a couple toggle switches. It not only gives you a four-way directional pad with center button, but a rotary “wheel” like on the old iPods. All of which you can access easily and with a minimum of wiring thanks to the wonders of I2C.
But even that might be selling the module short. This isn’t just a couple of buttons on a breakout board, the I2CNavKey is powered by its own PIC16F18345 microcontroller and features three configurable GPIOs with PWM support (perfect for an RGB LED) plus 256 bytes of onboard EEPROM storage.
[Saimon] has released the entire project as open source hardware for your hacking pleasure, but you can also get them as ready-to-use modules on Tindie for $18 USD [Editor’s Note: Because of a typo we originally we left the 1 out of the price]. Whether you’re a paying customer or not, you get access to the project’s absolutely phenomenal documentation, including a nearly 30 page manual that contains everything you’d ever want to know about the I2CNavKey and how to integrate it into your project. If all hardware was documented with this level of dedication, the world would be a much nicer place for folks like us.
Visitors to the Wizarding World of Harry Potter at Universal Studios are able to cast “spells” by waving special interactive wands in the air. Hackers like us understand that there must be some unknown machinations happening behind the scenes to detect how the wands are moving, but for the kids wielding them, it might as well be real magic. So when his son asked to have a Harry Potter themed birthday party, [Adam Thole] decided to try recreating the system used at Universal Studios in his own home.
Components used in the IR streaming camera
The basic idea is that each wand has a reflector in the tip, which coupled with strong IR illumination makes them glow on camera. This allows for easy gesture recognition using computer vision techniques, all without any active components in the wand itself.
[Adam] notes that you can actually buy the official interactive wands from the Universal Studios online store, and they’d even work with his system, but at $50 USD each they were too expensive to distribute to the guests at the birthday party. His solution was to simply 3D print the wands and put a bit of white prismatic reflective tape on the ends.
With the wands out of the way, he turned his attention to the IR imaging side of the system. His final design is a very impressive 3D printed unit which includes four IR illuminators, a Raspberry Pi Zero with the NoIR camera module. [Adam] notes that his software setup specifically locks the camera at 41 FPS, as that triggers it to use a reduced field of view by essentially “zooming in” on the image. If you don’t request a FPS higher than 40, the camera will deliver a wider image which didn’t have any advantage in this particular project.
The last part of the project was taking the video stream from his IR camera and processing it to detect the bright glow of a wand’s tip. For each frame of the video the background is first removed and then any remaining pixel that doesn’t exceed a set brightness level if ignored. The end result is an isolated point of light representing the tip of the wand, which can be fed into Open CV’s optical flow function to show [Adam] what shape the user was trying to make. From there, his software just needs to match the shape with one of the stock “spells”, and execute the appropriate function (such as changing the color of the lights in the room) with Home Assistant.
Overall, it’s an exceptionally well designed system considering the goal was simply to entertain a group of children for a few hours. We almost feel bad for the other parents in the neighborhood; it’s going to take more than a piñata to impress these kids after [Adam] had them conjuring the Dark Arts at his son’s party.
It wouldn’t be much of a stretch to assume that anyone reading Hackaday regularly has at least progressed to the point where they can connect an LED to a microcontroller and get it to blink without setting anything on fire. We won’t even chastise you for not doing it with a 555 timer. It’s also not a stretch to say if you can successfully put together the “Hello World” of modern electronics on a breadboard, you’re well on the way to adding a few more LEDs, some sensors, and a couple buttons to that microcontroller and producing something that might come dangerously close to a useful gadget. Hardware hacking sneaks up on you like that.
Here’s where it gets tricky: how many of us are still stuck at that point? Don’t be shy, there’s no shame in it. A large chunk of the “completed” projects that grace these pages are still on breadboards, and if we had to pass on every project that still had a full-on development board like the Arduino or Wemos D1 at its heart…well, let’s just say it wouldn’t be pretty.
Of course, if you’re just building something as a personal project, there’s often little advantage to having a PCB spun up or building a custom enclosure. But what happens when you want to build more than one? If you’ve got an idea worth putting into production, you’ve got to approach the problem with a bit more finesse. Especially if you’re looking to turn a profit on the venture.
At the recent WOPR Summit in Atlantic City, there were a pair of presentations which dealt specifically with taking your hardware designs to the next level. Russell Handorf and Mike Kershaw hosted an epic four hour workshop called Strategies for your Projects: Concept to Prototype and El Kentaro gave a fascinating talk about his design process called Being Q: Designing Hacking Gadgets which together tackled both the practical and somewhat more philosophical aspects of building hardware for an audience larger than just yourself.
[Glen]’s project sounds perfectly straightforward: have a big industrial-style push button act as a one-key USB keyboard. He could have hacked something together in any number of ways, but instead he decided to create a truly elegant solution. His custom PCB mates to the factory parts perfectly, and the USB cable between the button and the computer even fits through the button enclosure’s lead hole.
It turns out that industrial push buttons have standardized components which can be assembled in an almost LEGO-like manner, with components mixed and matched to provide different switch actions, light indicators, and things of that nature. [Glen] decided to leverage this feature to make his custom PCB (the same design used in his one-key keyboard project) fit just like a factory component. With a 3D printed adapter, the PCB locks in just like any other component, and even lines up with the lead hole in the button’s enclosure for easy connecting of the USB cable.
What does [Glen] use the big button for? Currently he has two applications: one provides a simple, one-button screen lock on a Linux box running a virtual machine at his place of work. It first disengages the keyboard capture of the virtual machine, then engages the screen lock on the host. The other inserts a poop emoji into Microsoft documents. Code and PCB design files for [Glen]’s small keyboards are available on GitHub.
In these days of cheap microcontrollers, it is hard to remember there was a time when timing things took real circuitry. Even today, for some applications it is hard to beat the ubiquitous 555 timer IC. It is cheap, plentiful, and reliable. What’s interesting about the 555 is it isn’t so much a dedicated chip as a bunch of building blocks on a chip. You can wire those building blocks up in different ways to get different effects, and [learnelectronics] has a video showing the three major modes you typically see with the 555: astable, bistable, and monostable.
The 555 is really only a few comparators, a voltage divider, one or two transistors, a flip flop and an inverter. The idea is you use a capacitor to charge and the comparators can set or reset the flip flop in different ways. A reset input or the flip flop can turn on the transistor to discharge the capacitor.
When Maxim acquired Dallas Semiconductor, they took over the popular 1-Wire product line. These are sensors that get power and bidirectional data over the same pin. However, we never liked the name 1-Wire as you really need two wires: one for the power and data and, of course, a ground wire. A new startup company, Cyclopia, has announced their latest line of truly one pin CPUs, and we’re impressed. The low power system on chip devices multiplex data, power, clock, and ground on one wire.
A company spokesperson, [Star Lipfir], noted, “Our patent-pending technology uses two well-known effects. First, a FET gate doesn’t actually draw current but works on an electric charge. Second, capacitors store charge.”
It turns out that industrial push buttons have standardized components which can be assembled in an almost LEGO-like manner, with components mixed and matched to provide different switch actions, light indicators, and things of that nature. [Glen] decided to leverage this feature to make his custom PCB (the same design used in his 
