Guide: Why Etch A PCB When You Can Mill?

I recall the point I started taking electronics seriously, although excited, a sense of dread followed upon the thought of facing the two main obstacles faced by hobbyists and even professionals: Fabricating you own PCB’s and fiddling with the ever decreasing surface mount footprints. Any resistance to the latter proves futile, expensive, and frankly a bit silly in retrospect. Cheap SMD tools have made it extremely easy to store, place, and solder all things SMD.

Once you’ve restricted all your hobbyist designs/experiments to SMD, how do you go about producing the PCBs needed for prototyping? Personally, I dread the thought of etching my own boards. The process is laborious and involves messy chemicals and specially sensitized PCB’s — none of which interest me. I’ve only ever done it a few times, and have promised myself never to do it again. Professional but cheap PCB manufacturing is more like it board pooling services such as OSH park have made this both easy and affordable — if you can wait for the turnaround.

So what are the alternatives? If you are really serious about swift prototyping from your own Lab, I put forth the case of milling your own PCB’s. Read on as I take you through the typical workflow from design to prototype and convince you to put up with the relatively high start up cost of purchasing a PCB mill.

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Upgrading A 3D Printer With OctoPrint

If you’ve been hanging around 3D printing communities, or reading the various 3D printing posts that have popped up here on Hackaday, you’ve almost certainly heard of OctoPrint. Created and maintained by Gina Häußge, OctoPrint allows you to turn an old computer (or more commonly a small ARM board like the Raspberry Pi or BeagleBone) into a network-accessible control panel for your 3D printer. Thanks to a thriving collection of community developed plugins, it can even control other hardware such as lights, enclosure heaters, smart plugs, or anything else you can think to hook onto the GPIO pins of your chosen ARM board. The project has become so popular that the new Prusa i3 MK3 has a header on the control board specifically for connecting a Pi Zero W running OctoPrint.

Even still, I never personally “got” OctoPrint. I was happy enough with my single printer connected to my computer and controlled directly from my slicer over USB. The majority of the things I print are of my own design, so when setting up the printer it only seemed logical that I would have it connected to the machine I’d be doing my designing on. If I’m sitting at my computer, I just need to rotate my chair to the right and I’m at my printer. What do I need to control the thing over WiFi for?

But things got tricky when I wanted to set up a second printer to help with speeding up larger projects. I couldn’t control them both from the same machine, and while I could print from SD on the second printer if I really had to, the idea seemed painfully antiquated. It would be like when Scotty tried talking into the computer’s mouse in “Voyage Home”. Whether I “got it” or not, I was about to dive headfirst into the world of OctoPrint.

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When A Skimmer Isn’t A Skimmer

I have a confession to make: ever since the first time I read about them online, I’ve been desperate to find an ATM skimmer in the wild. It’s the same kind of morbid curiosity that keeps us from turning away from a car accident, you don’t want to be witness to anyone getting hurt, but there’s still that desire to see the potential for danger up close. While admittedly my interest is largely selfish (I already know on which shelf I would display it), there would still be tangible benefits to the community should an ATM skimmer cross my path. Obviously I would remove it from the machine and prevent others from falling prey to it, and the inevitable teardown would make interesting content for the good readers of Hackaday. It’s a win for everyone, surely fate should be on my side in this quest.

So when my fingers brushed against that unmistakable knobby feel of 3D printed plastic as I went to insert my card at a local ATM, my heart skipped a beat. After all these years, my dream had come true. Nobody should ever be so excited about potentially being a victim of fraud, but there I was, grinning like an idiot in the farmer’s market. Like any hunter I quickly snapped a picture of my quarry for posterity, and then attempted to free it from the host machine.

But things did not go as expected. I spend most of my free time writing blog posts for Hackaday, so it’s safe to say that physical strength is not an attribute I possess in great quantity, but even still it seemed odd I couldn’t get the skimmer detached. I yanked it in every direction, tried to spin it, did everything short of kicking it; but absolutely no movement. In fact, I noticed that when pulling on the skimmer the whole face plate of the ATM bulged out a bit. I realized this thing wasn’t just glued onto the machine, it must have actually been installed inside of it.

I was heartbroken to leave my prize behind, but at the very least I would be able to alert the responsible party. The contact info for the ATM’s owner was written on the machine, so I emailed them the picture as well as all the relevant information in hopes that they could come check the machine out before anyone got ripped off.

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Great People And Culture At 34th Chaos Communication Congress

If you’ve been to a Chaos Communication Congress, you know the feeling — the strange realization after it’s all over that you’re back in the “real world”. It’s somehow alienating and unfriendly in comparison to being surrounded by computer freaks, artists, hackers, activists, coders, and other like-minded individuals over the four days of the Congress. A hand-written poster by the podcasting center read “Endlich, normale Leute” — “At last, normal people” — which is irony piled on irony but the sentiment is still right for certain strange values of “normal”. Normal hackers? You’d probably fit right in.

We cover a lot of the talks from the Congress, because they’re first-class and because you can play along at home, but the real soul of the Congress is people getting together, making something temporary and crazy, talking over their common plans, learning new things directly from one-another, and simply having fun. Here’s our chance to give you a little of the other side of the Congress.
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34C3: North Korea’s Consumer Technology

[Will Scott] and [Gabe Edwards] shed some light on the current state of consumer computing technology at 34C3 in their talk DPRK Consumer Technology. The pair has also created a website to act as a clearinghouse for this information — including smartphone OS images up at koreaComputerCenter.org.

Not a whole lot is known about what technology North Korean citizens have available to them. We have seen Red Star OS, the Mac-like Linux based operating system used on PC based desktops. But what about other systems like smartphones?

[Will] and [Gabe] found that cell phones in North Korea are typically manufactured by Chinese companies, running a custom version of the Android Operating system. The phone hardware is common — the phone sold as the Pyongyang 2407 in North Korea is also sold in India as the Genie v5. If you can get your hands on the Genie, you can run the Korean version of the Android OS on that hardware.

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Laptop With Raspberry Pi Inside Learns To Speak Battery

Early in November we took a look at a one of the best Raspberry Pi laptops we had ever seen, using the shell of a Sony VAIO. Laptops used to be hulking beasts, and that played into [Frank Adams’] hands as he got rid of the motherboard and had enough space to replace it with a Raspberry Pi and a few other support boards. This took advantage of the laptop’s screen, keyboard, LEDs, etc. But what’s a laptop without battery power? [Frank] hadn’t cracked that nut until now.

Inside of Sony VAIO laptop turned Raspberry Pi computer
VAIO battery and charging PCB seen to lower left

Adding battery power is trickier that it sounds, but [Frank] managed to get the Raspberry Pi to talk to the original Sony VAIO internal battery. His work on the project is shared, but this part of the story is best found starting on page 29 of his PDF project details.

Using the original battery is a good move since it’s designed to fit and has a charger ready to interface with the port on the laptop case. But these batteries have logic inside them, and there’s the rub. Communications use the 2-wire System Management Bus (SMBus) which is well documented. But the when trying to use the Pi’s I2C [Frank] couldn’t figure out to send a repeated start command.

He ended up writing his own C program that bit-bangs the communications he needed and now has the Pi speaking to the battery and listening to what it hears coming back. Reading through his description of this is fun since he includes his observations from a logic analyzer captures. He suspects an occasional bad read is due to Linux interrupting code execution. He watches for and catches these bad reads in software and can now reliably read all the battery vitals.

The hack leaves him with a system that functions in much the same way the original computer did: plug it in and it charges. He did add some hardware that lets him take a voltage reading from the battery using an ADC on the Teensy that was already present to control the keyboard and case LEDs. This adds a small constant draw on the battery, but for now he doesn’t leave the battery connected when the laptop is not in use.

If you’d like to read our original coverage of this laptop, here it is.

34C3: Hacking The Nintendo Switch

There’s a natural order to the world of game console hacking: every time a manufacturer releases a new game console they work in security measures that prevent the end user from running anything but commercially released games, and in turn every hacker worth his or her salt tries to break through. The end goal, despite what the manufacturers may have you believe, is not to run “bootleg” games, but rather to enable what is colloquially referred to as “homebrew”. That is to say, enabling the novel concept of actually running software of your choice on the hardware you paid for.

At 34C3, noted console hackers [Plutoo], [Derrek], and [Naehrwert] have demonstrated unsigned code running on Nintendo’s latest and greatest and while they are keeping the actual exploit to themselves for now, they’ve promised that a platform for launching homebrew is coming shortly for those who are on firmware version 3.0.0. From the sound of it, after 9 months on the market, Switch owners will finally have complete access to the hardware they purchased.

The key to running the team’s own code was through a WebKit exploit that was already months old by the time the Switch was released. Loading up an arbitrary webpage was the tricky part, as the Switch generally uses its web browser for accessing official sources (like the online game store). But hidden away in the help menus of Tetris, the developers helpfully put a link to their website which the Switch will dutifully open if you select it. From there it’s just a matter of network redirection to get the Switch loading a webpage from your computer rather than the Internet.

It’s easier to ask for forgiveness than permission.

But as the more security-minded of our readers may have guessed already, that just gets you into the browser’s sandbox. The team now had to figure out a way to break out and get full control of the hardware. Through a series of clever hacks the team was able to learn more about the Switch’s internal layout and operating system, slowly working their way up the ladder.

A particularly interesting hack was used to get around a part of the Switch’s OS that is designed to check which services code is allowed to access. It turns out that if code doesn’t provide this function with its own process ID (PID), the system defaults to PID 0 because the variable is not initialized. In other words, if you don’t ask the operating system which functions you have access to, you will get access to them all. This is a classic programming mistake, and a developer at Nintendo HQ is likely getting a very stern talking to right about now.

But not everything was so easy. When trying to get access to the boot loader, the team sniffed the eMMC bus and timed the commands to determine when it was checking the encryption keys. They were then able to assemble a “glitcher” which fiddled with the CPU’s power using FPGA controlled MOFSETs during this critical time in an attempt to confuse the system.

The rabbit hole is pretty deep on this one, so we’d recommend you set aside an hour to watch the entire presentation to see the long road it took to go from a browser bug to running their first complete demo. It’s as much a testament to the skill of  [Plutoo], [Derrek], and [Naehrwert] as it is the lengths at which Nintendo went to keep people out.

We’ve seen other attempts at reverse engineering Nintendo’s hardware, but by the looks of it, the Switch has put up a much harder fight than previous console generations. Makes you wonder what tricks Nintendo will have up their sleeves for the next generation.

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