Enjoying Some Exothermic Welding, With Thermite!

July 30, 2020 by Maya Posch 21 Comments

There probably aren’t many people out there who aren’t aware of what thermite is and how it demonstrates the power of runaway exothermic reactions. Practical applications that don’t involve destroying something are maybe less known. This is where the use of thermite for creating welds is rather interesting, as shown in this video by [Finn] that is also embedded after the break.

In the video, one can see how [Finn] uses thermite charges to weld massive copper conductors together in a matter of seconds inside a graphite mold. Straight joints, T-joints, and others are a matter of putting the conductors into the mold, pushing a button and watching the fireworks. After a bit of cleaning the slag off, a solid, durable weld is left behind.

The official name for this process is ‘exothermic welding‘, and it has been in use since the 19th century. Back then it was used primarily for rail welding. These days it sees a lot of use in high-voltage wiring and other applications, as in the linked video. The obvious advantage of exothermic welding is that the resulting joint is strong and durable, on account of the two surfaces having been permanently joined.

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Breakaway Keyboard PCB Makes Customization A Snap

July 29, 2020 by Kristina Panos 18 Comments

Once upon a time, keyboards were something that you took with you from computer to computer, because most of them were built quite nicely. After a few dark decades of membrane keyboards being the norm, the rise of the mechanical keyboard community has shined a light on what is possible with open source designs. Anyone can join in, because quality clackers now exist on every level, whether you want to design the perfect split ortho with OLEDs, rotary encoders, and rear view mirrors, or just want to fork over some money and get to punching switches.

Break me off a piece of that candy bar keeb.

Building your own keyboard doesn’t have to be daunting. It can be as easy or as involved as you want. There’s still a fair amount of soldering simply because it’s a keyboard. But there are plenty of options if you don’t want to do a whole lot beyond soldering switches (or hot swap sockets!) and putting a case together.

Take for instance the JNAO (Just Need An Ortho) build that [Jared] just finished. It starts with a PCB and on-board controller, and the idea is to customize it from there. You’re left to 3D print, laser cut, or otherwise carve your own case and a plate to stabilize the key switches, and then get down to business deciding on switches and keycaps.

The interesting thing about the JNAO is the breakaway row of keys on the bottom. The standard grid is 12×5, but if you don’t need the dedicated number row along the top like [Jared], you’re not stuck with it. And you’re not stuck with the default layout, either. Flashing to a standard Planck layout didn’t go as easily as [Jared] might have liked, but we think he was wise to get the firmware squared away before ever turning on the soldering iron.

Don’t know what to do with such a small keyboard? They’re pretty much perfect for cyberdeck builds.

Trick From 1903 Makes An Old Monochrome TV Spit Some Colours

July 28, 2020 by Adil Malik 26 Comments

Its safe to say that colour television is taken for granted nowadays. Consumed by the modern marketing jargon of colour dynamic range, colour space accuracy and depth, it is easy to overlook the humble beginnings of image reproduction when simply reconstructing an image with the slightest hint of colour required some serious ingenuity and earned you a well deserved pat on the back!

[anfractuosus] revisited an old gem of a technique, first patented in 1903 and used it to successful make an old monochrome TV produce a colour image. The idea in essence, is actually similar to what cheap image sensors and LCDs still use today. Rather than relying on true RGB colour generation by individually integrating colour sources as AMOLED does, we take an easier route: Produce a simpler monochrome image where each colour pixel is physically represented by four monochrome sub-pixels, one for each colour component. Now light up each of the sub-pixels according to the colour information of your image and rely on an external colour filter array to combine and spit out the correct colours.

He first used some image processing to convert a standard colour video into the aforementioned monochrome sub-pixel representation. Next, a Bayer colour filter array was printed on some acetate sheets using an inkjet printer (the original inventors used potato starch!), which when overlaid on top of the monochrome monitor, magically result in colour output.

There are some problems associated with this technique, mainly to do with the difficulty in measuring the size of the TV pixels and then producing and perfectly aligning a filter sheet for it. You should check out how [anfractuosus] went about solving those issues.

So now you know a bit more about colour image generation, but how about colour TV transmission? Check out an earlier piece to learn more.

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Polymorphic String Encryption Gives Code Hackers Bad Conniptions

July 27, 2020 by Lewin Day 26 Comments

When it comes to cyber security, there’s nothing worse than storing important secret data in plaintext. With even the greenest malicious actors more than capable of loading up a hex editor or decompiler, code can quickly be compromised when proper precautions aren’t taken in the earliest stages of development. To help avoid this, encryption can be used to hide sensitive data from prying eyes. While a simple xor used to be a quick and dirty way to do this, for something really sophisticated, polymorphic encryption is a much better way to go.

A helpful tool to achieve this is StringEncrypt by [PELock]. An extension for Visual Studio Code, it’s capable of encrypting strings and data files in over 10 languages. Using polymorphic encryption techniques, the algorithm used is unique every time, along with the encryption keys themselves. This makes it far more difficult for those reverse engineering a program to decrypt important strings or data.

While the free demo is limited in scope, the price for the full version is quite reasonable, and we expect many out there could find it a useful addition to their development toolkit. We’ve discussed similar techniques before, often used to make harder-to-detect malware.

[Thanks to Dawid for the tip!]

Mechanical Seven-Segment Display Really Sticks Out From The Pack

July 27, 2020 by Dan Maloney 20 Comments

We’ve been displaying numbers using segmented displays for almost 120 years now, an invention that predates the LEDs that usually power the ubiquitous devices by a half-dozen decades or so. But LEDs are far from the only way to run a seven-segment display — check out this mechanical seven-segment display for proof of that.

We’ve been seeing a lot of mechanical seven-segment displays lately, and when we first spotted [indoorgeek]’s build, we thought it would be a variation on the common “flip-dot” mechanism. But this one is different; to form each numeral, the necessary segments protrude from the face of the display slightly. Everything is 3D-printed from white filament, yielding a clean look when the retracted but casting a sharp shadow when extended. Each segment carries a small magnet on the back which snuggles up against the steel core of a custom-wound electromagnet, which repels the magnet when energized and extends the segment. We thought for sure it would be loud, but the video below shows that it’s really quiet.

While we like the subtle contrast of the display, it might not be enough for some users, especially where side-lighting is impractical. In that case, they might want to look at this earlier similar display and try contrasting colors on the sides of each segment.

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Tiny Circuit Sculpture Keeps The Night Watch

July 27, 2020 by Kristina Panos 8 Comments

If you’re planning to get into circuit sculpture one of these days, it would probably be best to start with something small and simple, instead of trying to make a crazy light-up spaceship or something with a lot of curves on the first go. A small form factor doesn’t necessarily mean it can’t also be useful. Why not start by making a small automatic night light?

The circuit itself is quite simple, especially because it uses an Arduino. You could accomplish the same thing with a 555, but that’s going to complicate the circuit sculpture part of things a bit. As long as the ambient light level coming in from the light-dependent resistor is low enough, then the two LEDs will be lit.

We love the frosted acrylic panels that [akshar1101] connected together with what looks like right angle header pins. If you wanted to expose the electronics, localize the light diffusion with a little acrylic cover that slips over the LEDs. Check it out in the demo after the break.

There’s more than one way to build a glowing cuboid night light. The Rubik’s way, for instance.

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Ergo Keyboard Build Issue Becomes Crystal Clear

July 23, 2020 by Kristina Panos 4 Comments

Somewhere between the onset of annoying hand pain and the feeling of worn-out, mushy switches, [sinbeard]’s keyboard dissatisfaction came to a head. He decided it was time to slip into something bit more ergonomic and settled on building an Iris — a small split keeb with an ortholinear (non-staggered) key arrangement.

The Iris is open source and uses an on-board controller, so you can have the boards fabbed and do a lot of SMD soldering, or get a pair of PCBs with all of that already done. [sinbeard] went the latter route with this build, but there’s still plenty of soldering and assembly to do before it’s time to start clackin’, such as the TRRS jacks, the rotary encoders, and of course, all the switches. It’s a great way for people to get their feet wet when it comes to building keyboards.

Everything went according to plan until it was time to flash the firmware and it didn’t respond. It’s worth noting that both of the Iris PCBs are the same, and both are fully populated. This is both good and bad.

It’s bad you have two on-board microcontrollers and their crystals to worry about instead of one. It’s good because there’s a USB port on both sides so you can plug in whichever side you prefer, and this comes in mighty handy if you have to troubleshoot.

When one side’s underglow lit up but not the other, [sinbeard] busted out the ISP programmer. But in the end, he found the problem — a dent in the crystal — by staring at the board. A cheap replacement part and a little hot air rework action was all it took to get this Iris to bloom.

Want to build a keyboard but need a few more keys? Check out the dactyl and the ErgoDox.