Noble Graphs: Displaying Data With Neon Like Its 1972

October 17, 2023 by Adam Zeloof 12 Comments

In the days before every piece of equipment was an internet-connected box with an OLED display, engineers had to be a bit more creative with how they chose to communicate information to the user. Indicator lights, analog meters, and even Nixie tubes are just a few of the many methods employed, and are still in use today. There are, however, some more obscure (and arguably way cooler) indicators that have been lost to time.

[Aart Schipper] unearthed one such device while rummaging around in his father’s shed: a pair of Burroughs Bar Graph Glow-Transfer Displays. These marvelous glowing rectangles each have two bars (think the left and right signals on an audio meter, which is incidentally what they were often used for), each with 201 neon segments. Why 201, you may ask? The first segment on each bar is always illuminated, acting as a “pilot light” of sorts. This leaves 200 controllable segments per channel. Each segment is used to “ignite” its neighboring segment, something the manufacturer refers to as the “Glow-Transfer Principle.” By clever use of a three-phase clock and some comparators, each bar is controlled by one analog signal, keeping the wire count reasonably low.

Don’t get us wrong, the warm, comforting glow of Nixie tubes will always have a special place in our hearts, but neon bar graphs are just hard to beat. The two do have a similar aesthetic though, so here’s hoping we see them used together in a project soon.

Thanks to [Jan] for the tip!

Silicon Photolithography The PCB Way

October 17, 2023 by Dan Maloney 3 Comments

[ProjectsInFlight] has been doing some fantastic work documenting his DIY semiconductor fab lately. Next up: exploring down-and-dirty photolithography methods.

If you’ve been following along with this series — and why wouldn’t you? — you’ll recall [ProjectsInFlight]’s earlier experiments, like creating oxide layers on silicon chips with a homebrew tube furnace and exploring etchants that can selectively remove them. But just blasting away the oxide layer indiscriminately isn’t really something you need to do when etching the fine features needed to fabricate a working circuit. The trouble is, most of the common photoresist solutions used by commercial fabs are unobtainium for hobbyists, leading to a search for a suitable substitute.

Surprisingly, PCB photoresist film seemed to work quite well, but not without a lot of optimization by [ProjectsInFlight] to stick it to the silicon using a regular laminator. Also in need of a lot of tweaking was the use of a laser printer to create masks for the photolithography process on ordinary transparency film, including the surprisingly effective method of improving the opacity of prints with acetone vapor. There were also extensive experiments to determine the best exposure conditions, a workable development process, and the right etchants to use. Watch the video below for a deep dive into all those topics as well as the results, which are pretty good.

There’s a lot to be said for the methodical approach that [ProjectsInFlight] is taking here. Every process is explored exhaustively, with a variety of conditions tested before settling on what works best. It’s also nice to see that pretty much all of this has been accomplished with the most basic of materials, all of which are easily sourced and pretty cheap to boot. We’re looking forward to more of the same here, as well as to see what others do with this valuable groundwork.

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Memorialize Your Favorite Chips In Slate

October 15, 2023 by Tom Nardi 10 Comments

There’s no point in denying it — if you’re a regular reader of Hackaday, you’ve almost certainly got a favorite chip. Some in the audience yearn for the simpler days of the 6502, while others spend their days hacking on modern microcontrollers like the ESP32 or RP2040. There are even some of you out there still reaching for the classic 555. Whatever your silicon poison, there’s a good chance the Macrochips project from [Jason Coon] has supersized it for you.

The idea is simple: get a standard 100 mm x 100 mm (4″ x 4″) slate coaster, throw it in your laser engraver of choice, and zap it with a replica of a chip’s label. The laser turns the slate a light gray, which, when contrasted with the natural color of the slate, makes for a fairly close approximation of what the real thing looks like. To date, [Jason] has given more than 140 classic and modern chips the slate treatment. Though he’s only provided the SVGs for a handful of them, we’re pretty sure anyone with a laser at home will have the requisite skills to pull this off without any outside assistance.

The page credits a post from [arturo182] for the idea (Nitter), which pointed out a slate RP2040 hiding out on the corner of [Graham Sanderson]’s desk back in 2021. We just became aware of the trend when [Jason] posted his freshly engraved RP1 on Mastodon in honor of the release of the Raspberry Pi 5.

Burnt Resistor Sleuthing

October 15, 2023 by Al Williams 7 Comments

You smell smoke and the piece of gear you are working on stops working, probably at an inopportune time. You open it up and immediately see the burned remains of a resistor. You don’t have the schematic, the Internet has nothing to say, and the markings on the resistor are burned away. What do you do? [Learn Electronics Repair] has some advice.

The resistor is probably open, but even if it isn’t, you can’t count on any measurement you make. The burning could easily change the value. The technique comes from comments on one of his earlier videos where he had such a burned resistor but was able to find the correct value. He decided to test the suggestion: cut away the burned resistor and measure the pieces that are left. It probably won’t give you the exact value, but it will get you in the ballpark.

So a rotary tool did the surgery, and you can see it all in the video below. We aren’t sure this method would work on every type of resistor you might encounter, and surface mount will also present special problems. However, if you are stabbing in the dark anyway, it won’t hurt to try.

Everyone knows the smoke that comes out is magic. Sometimes, you cut into components by necessity. Other times, it is for art’s sake.

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Lessons Learned: Plastic Injection Molding For Products

October 14, 2023 by Donald Papp 23 Comments

Injection molding is one of the technologies that makes the world go round. But what does it actually look like to go through the whole process to get a part made? [Achim Haug] wrote up a blog post that does a fantastic job of explaining what to expect when getting plastic enclosures injection molded in China.

These air quality monitors required a two-part enclosure.

Injection molding a part requires making a custom mold, which is then used by an injection molding machine in a shop to crank out parts. These are two separate jobs, but in China the typical business model is for a supplier to quote a price for both the mold as well as the part production. [Achim] describes not only what navigating that whole process was like, but also goes into detail on what important lessons were learned and shares important tips.

One of the biggest takeaways is to design the part with injection molding in mind right from the start. That means things like avoiding undercuts and changes in part thickness, as well as thinking about where the inevitable mold line will end up.

[Achim] found that hiring a been-there-done-that mold expert as a consultant to review things was a huge help, and well worth the money. As with any serious engineering undertaking, apparently small features or changes can have an outsized impact on costs, and an expert can recognize and navigate those.

In the end, [Achim] says that getting their air quality monitor enclosures injection molded was a great experience and they are very happy with the results, so long as one is willing to put the work in up front. Once the mold has been made, downstream changes can be very costly to make.

[Achim]’s beginning-to-end overview is bound to be useful to anyone looking to actually navigate the process, and we have a few other resources to point you to if you’re curious to learn more. There are basic design concerns to keep in mind when designing parts to make moving to injection molding easier. Some injection molding techniques have even proven useful for 3D printing, such as using crush ribs to accommodate inserted hardware like bearings. Finally, shadow lines can help give an enclosure a consistent look, while helping to conceal mold lines.

How Not To Build An RP2040 Board

October 11, 2023 by Al Williams 26 Comments

We love that these days you can buy ready-made microcontroller boards that are very capable. But sometimes you need to — or just want to — do it yourself. Unfortunately, you really should design everything twice: once to figure out where all the problems are, and the second time to do it better. If you want to create your own board for the RP2040 then you are in luck. [Jeremy] has made the first (and second) iteration or an RP2040 board and shares with us what he would not do again.

In all fairness, he also has a blog post talking about what he did, so you might want to start there. However, we think his most valuable advice was his final word: Don’t fail to get started on your design. The longest journey, after all, begins with the first step.

His other advice is good, too. For example, don’t plug your new board into a computer because an error in the power supply could take the whole computer out. He also warns you not to do like he did and forget to order the $10 solder stencil with the PCBs.

Some of it is just good advice in general. For example — buy more small components than you think you need. There’s nothing worse than needing three resistors, having three resistors, and then watching one of the three fly across the room or stick to your soldering iron and melt into a pool of slag. Buy ten and you’ll save money in the long run.

In the end, the board did work and what he learned might help you if you decide to tackle a similar project yourself. [Jeremy’s] board is fairly large, but if you have an appetite for something smaller, check out the RPDot or the RP2040 Stamp.

Pocket CO2 Sensor Doubles As SMD Proving Ground

October 10, 2023 by Tom Nardi 4 Comments

While for some of us it’s a distant memory, every serious electronics hobbyist must at some point make the leap from working with through-hole components to Surface Mount Devices (SMD). At first glance, the diminutive components can be quite intimidating — how can you possibly work with parts that are literally smaller than a grain of rice? But of course, like anything else, with practice comes proficiency.

It’s at this silicon precipice that [Larry Bank] recently found himself. While better known on these pages for his software exploits, he recently decided to add SMD electronics to his repertoire by designing and assembling a pocket-sized CO2 monitor. While the monitor itself is a neat gadget that would be worthy of these pages on its own, what’s really compelling about this write-up is how it documents the journey from SMD skeptic to convert in a very personal way.

A fine-tipped applicator will get the solder paste where it needs to go.

At first, [Larry] admits to being put off by projects using SMD parts, assuming (not unreasonably) that it would require a significant investment in time and money. But eventually he realized that he could start small and work his way up; for less than $100 USD he was able to pick up both a hot air rework station and a hotplate, which is more than enough to get started with a wide range of SMD components. He experimented with using solder stencils, but even there, ultimately found them to be an unnecessary expense for many projects.

While the bulk of the page details the process of assembling the board, [Larry] does provide some technical details on the device itself. It’s powered by the incredibly cheap CH32V003 microcontroller — they cost him less than twenty cents each for fifty of the things — paired with the ubiquitous 128×64 SSD1306 OLED, TP4057 charge controller, and a SCD40 CO2 sensor.

Whether you want to build your own portable CO2 sensor (which judging from the video below, is quite nice), or you’re just looking for some tips on how to leave those through-hole parts in the past, [Larry] has you covered. We’re particularly eager to see more of his work with the CH32V003, which is quickly becoming a must-have in the modern hardware hacker’s arsenal.

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