The 2022 Hackaday Prize Hack Chat Kicks Things Off

April 15, 2022 by Tom Nardi No comments

The 2022 Hackaday Prize is on, and we’ve already seen some incredible submissions by folks who believe their idea just might have what it takes to make the world a better place. But as with all contests, it’s good to understand all the rules before you get too involved. We promise nothing’s hidden in the fine print, but we certainly don’t fault anyone who wants to make sure.

Which is why Majenta Strongheart, Head of Design and Partnerships at our parent company Supplyframe, stopped by this week’s Hack Chat to answer any and all questions the community had about this global hardware design challenge. A lot of ground was covered in an hour, with Majenta making sure everyone’s questions and concerns were addressed to their satisfaction. After all, with a residency at the Supplyframe DesignLab and a total of $125,000 in prize money up for grabs, we want to make sure everyone’s got the facts straight.

So what burning questions did the Hackaday community have about this year’s Prize? Several people wanted to know more about the themes of sustainability, circularity, and climate crisis resiliency. For example, what exactly does circularity mean in this context? While Challenge #2 “Reuse, Recycle, Revamp” most clearly exemplifies the idea, Majenta explained that this time around the judges will be giving particular consideration to ideas that limit the extraction of raw materials and the production of waste.

For a practical example, 2022 Hackaday Prize judge James Newton pointed to the direct granule extruder designed by Norbert Heinz. The project, which took 5th place last year, allows waste plastic to easily be repurposed in a desktop 3D printer. This includes objects which the printer itself produced, but for whatever reason, are no longer desired or needed. This “life-cycle” for printed objects, wherein the same plastic can be printed over and over again into new objects, is a perfect encapsulation of circularity within the context of this year’s prize.

Others were looking for clarification on the contest rules. Specifically, there was some confusion about entering existing projects into the competition. Did it have to be a completely new idea? What if you’d already been working on the project for years, but had never shown it publicly before? Not to worry — existing projects can absolutely be entered into the 2022 Hackaday Prize. In fact, even if the project had already been entered into the Hackaday Prize previously, it’s still fair game.

But there is an important caveat: to be eligible for this year’s Prize, the project MUST be documented on a new Hackaday.io page. Additionally, if it’s a project that has previously been entered into a Hackaday contest, you’ll have to show that it is “significantly different from when previously entered and show meaningful development during the course of the Contest“, as stated in the official rules. In layman’s terms, it means that anyone who tries to submit and old and outdated Hackaday.io page into the competition will find their entry disqualified.

Towards the end of the Chat, Erin Kennedy, a Hackaday Prize veteran that readers may know better as “Erin RobotGrrl” brought up the subject of mentors. In previous years, hardware luminaries like Andrew “Bunnie” Huang and Mitch Altman were made available to offer advice and guidance to the individuals and teams behind the Prize entries. While very proud of this effort, Majenta explained that at least for now, Mentor Sessions are on hold until that aspect of the program can be retooled. The main issue is figuring out the logistics involved; planing video calls between several groups of busy folks is just as tricky as it sounds. That said, bringing the Mentor Sessions back for 2022 isn’t completely out of the question if there’s enough interest from the competitors.

We appreciate Majenta taking the time to directly answer questions from the community, and hope that those who had their questions or concerns addressed during the Chat will ultimately decide to toss their hat into the ring. With a worthy goal and plenty of opportunities to win, we sincerely want to see as many people as possible get their entries in before the October 16th deadline. If you’re ready to take the next step, head over to the Contest page and show us what you’ve got.

The Hack Chat is a weekly online chat session hosted by leading experts from all corners of the hardware hacking universe. It’s a great way for hackers connect in a fun and informal way, but if you can’t make it live, these overview posts as well as the transcripts posted to Hackaday.io make sure you don’t miss out.

The Open Source ASICs Hack Chat Redefines Possible

March 18, 2022 by Tom Nardi 4 Comments

There was a time when all that was available to the electronics hobbyist were passive components and vacuum tubes. Then along comes the integrated circuit, and it changed everything. Fast forward a bit, and affordable programmable microcontrollers arrived on the scene. Getting started in electronics became far easier, and the line between hardware and software started to blur. Much more recently, the hobbyist community was introduced to field programmable gate arrays (FPGAs) and the tools necessary to work with them. While not as widely applicable as the IC or MCU, the proliferation of FPGAs among hardware hackers once again opened doors that were previously locked tight.

We’re currently on the edge of another paradigm shift, but it’s no surprise if you haven’t heard of it. After all, the last couple of years have been a bit unusual, so the 2020 announcement that Google was teaming up with SkyWater and Efabless to enable the design and manufacture of open source application-specific integrated circuits (ASICs) flew under the radar for many people. But not Matt Venn, the host of this week’s Hack Chat. For him, it was the opportunity he’d been waiting for.

Matt started like many of us, building electronic kits and building new gadgets out of old discarded hardware. He graduated to microcontrollers, and became particularly interested in FPGAs when the open source toolchains started hitting the scene. Of course by this point, it was much more than just a hobby for him. He was presenting a talk at the 2019 Week of Open Source Hardware in Switzerland when he saw Tim Edwards from Efabless demo a chip that had been made with open source tools. Unfortunately, the costs involved were still far too high for an individual to put their ideas into silicon.

So when Google and Skywater announced they would be footing the bill to have selected open source ASIC designs manufactured a few months later, Matt says he was in a good position to jump in. He has since started running the Zero to ASIC Course which aims to teach you how to produce your own chips using the open source Process Development Kit, and so far 160 people have taken him up on the offer.

As you might expect, many of the questions in the Chat had to do with what kind of designs you can actually produce using the 130 nm process. Especially given the limits on the physical space each creator’s circuit can take up on each multi-project wafer (MPW). Others wanted to know how difficult it would be to port over existing FPGA designs, or how well the process worked with analog applications. With the number of designs Matt has seen go through his course, he could answer many of the questions just by pointing to a particular individual’s ASIC. For instance, he held up the digital-to-analog converter from Harald Pretl and Thomas Parry’s 5 GHz satellite transceiver as prime analog examples.

So let’s say you put the work in to design an ASIC and it gets approved to be produced on a future MPW, what then? Well, first you have to hope everything goes according to plan. Matt explains that the initial run was almost a total write-off due to timing problems in the toolchain, though in the end, he was largely able to recover his own chip. But they’ve done several runs since then, so let’s assume there’s no production problems. What exactly ends up on your doorstep?

If you were expecting a handy DIP8, you might be disappointed. While some DIY friendly packages would be nice, right now the ASICs ship as wafer level chip scale package (WLCSP) with an unforgiving 0.5 mm pitch. If you can believe it, that’s actually an improvement over the first run, which shipped out as a bare die. Of course as Matt pointed out, anyone who’s gotten to the point of designing their own custom ASIC probably won’t be scared off by the prospect of some fine-pitch soldering. Some in the Chat wondered about the difficulty in getting compatible PCBs produced, but Matt said that in his experience OSH Park has been up to the challenge.

Like the Metal 3D Printing Hack Chat before it, this week’s session went over a topic that’s on the absolute cutting edge of what’s possible for hardware hackers and hobbyists. Truth be told, the vast majority of the people reading Hackaday are no more likely to send away for their own custom ASIC as they are to battle x-rays in an attempt to sinter metal with a homebrew electron gun. But that doesn’t make the fact that some folks out there doing it any less important, or inspiring. That said, if you do end up being one of those select few that can boast they’ve designed a custom chip of their own — don’t forget to send one of them our way.

We’re grateful Matt Venn was able, once again, to share his valuable experience in the realm of open source application-specific integrated circuits with us. If you haven’t checked them out already, the Zero to ASIC workshop he ran for Remoticon 2020 and his talk Open Source ASICs – A Year in Perspective from Remoticon 2021 are required viewing if you want to learn more about this fascinating new frontier in hardware hacking.

The Metal 3D Printing Hack Chat Brings The Heat

March 11, 2022 by Tom Nardi 8 Comments

At this point, it’s safe to say the novelty of desktop 3D printing has worn off. The community has largely come to terms with the limitations of extruded plastics, and while we still vehemently believe that it’s a transformative technology, we’ll admit there aren’t too many applications where a $200 USD printer squirting out PLA is truly the best tool for the job.

But rather than looking at today’s consumer 3D printer market as the end of the line, what if it’s just the beginning? With the problems of slicing, motion control, and extrusion more or less solved when it comes to machines that print in plastic, is it finally time to turn our attention to the unique problems inherent in building affordable metal printers? Agustin Cruz certainly thinks so, which is why he took to the Hack Chat this week to talk about his personal vision for an open source 3D printer that can turn powdered metals into solid objects by way of a carefully controlled electron beam.

To be clear, Agustin isn’t suggesting you toss out your Creality anytime soon. Metal 3D printing will always be a niche within a niche, but for applications where even advanced engineering plastics like PEI and PEEK simply won’t do, he argues the community needs to have a cheap and accessible option. Especially for developing and low income countries where traditional manufacturing may be difficult. The machine he’s been working on wouldn’t be outside the capabilities of an individual to build and operate, but at least for right now the primary target is hospitals, colleges, and small companies.

The Chat was full of technical questions about Agustin’s design, and he wasn’t shy about tackling them. Some wondered why he decided to sinter the metal powder with an electron gun when solid-state lasers are cheap, easily available, and relatively straightforward to work with. But while the laser might seem like the easier solution on the surface, Agustin points out that using a magnetically focused electron beam gives his printer some unique capabilities.

For example, he can easily defocus the beam and pass it over the entire build plate to pre-heat the powder. The steerable beam doesn’t require mirrors either, which not only reduces the weight and complexity of the machine, but in theory should allow for faster print speeds. The beam can be moved in the X/Y dimensions with an accuracy of 0.01 mm, and while the beam diameter is currently a respectable 0.5 mm, Agustin says he’s working on bringing that down to 0.1 mm for high detail work. The temperature at the focal point of the beam is between 1,400 and 1,500 °C, which he notes is not only hot enough to melt the powdered metal, but can also weld stainless steel.

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Al Williams Tells All In The Logic Simulation Hack Chat

March 4, 2022 by Tom Nardi 1 Comment

The list of requirements for hosting one of our weekly Hack Chats is pretty short: you’ve got to be knowledgeable, passionate, and above all else, willing to put those two quantities on display for a group of like-minded strangers. Beyond that, we’re not too picky. From industry insider to weekend hobbyist, high school dropout to double doctorate, if you’ve got something interesting to talk about, we’re ready to listen.

But in casting a such a wide net, we occasionally forget that we’ve got a considerable collection of potential hosts within our own worldwide roster of contributors. Among this cast of characters, few can boast the same incredible body of knowledge as Al Williams, who was able to pencil in some time this week to host the Logic Simulation Hack Chat.

Or at least, that was the idea. In reality the Chat covered a wide range of topics, and was peppered with fascinating anecdotes pulled from Al’s decades of experience in the field. Though to be fair, we expected no less. He was building hardware before many of us were born, and can take credit for designs that have been at the bottom of the ocean as well as launched into orbit. He’s been writing about it just as long too, with articles of his appearing in iconic print magazines such as Dr. Dobb’s Journal.

Al has seen and done so much that he still surprises us with the occasional nugget, and we’ve been working with him for years. It was only a week or two back that he started a story with “Back when I used to manage a gas pipeline…” in the middle of a conversation about utility metering.

Of course, that’s not to say some technical discussion didn’t sneak in there from time to time. Sure Al’s recollection of how they used to literally crawl over the schematics for the 68000 back at Motorola might stick out as a particular high point, but he also explains his personal preference for vendor-specific software tools over their more generic open source counterparts. He also draws comparisons between hardware description languages (HDLs) like Verilog and parametric CAD tools such as OpenSCAD in the way that they help model complex relationships in ways that can’t be easily done by more traditional means.

At one point the conversation lingers on the design and production of application-specific integrated circuits (ASICs), and how they compare to field-programmable gate arrays (FPGAs). Traditionally ASICs have been out of reach for the hobbyist, but with the recent collaboration between Google and SkyWater Technology to create an open source process design kit (PDK), they’re now within the capabilities of a dedicated individual. Matt Venn spoke on the topic during Remoticon 2021, and it’s good to see more folks in the community openly discussing the possibilities of custom silicon designed by hackers.

From there, things start really getting wild. From dreaming of virtual reality circuit simulators that let you fly amongst your creations like in Tron, to salivating over high-end technologies such as reflective memory, this Chat really runs the gamut. But then, that’s sort of why we hold them in the first place. Whether you actively participate or are just along for the ride, the Hack Chat gives everyone in the community a chance to gather around a virtual water cooler with fascinating characters that you won’t find anywhere else.

Pick And Place Hack Chat Reveals Assembly Secrets

February 11, 2022 by Tom Nardi 9 Comments

These days we’ve got powerful free tools to do CAD and circuit design, cheap desktop 3D printers that can knock out bespoke enclosures, and convenient services that will spin up a stack of your PCBs and send them hurtling towards your front door for far less than anyone could have imagined. In short, if you want to build your own professional-looking gadgets, the only limit is your time and ambition. Well, assuming you only want to build a few of them, anyway.

Once you start adding some zeros to the number of units you’re looking to produce, hand assembling PCBs quickly becomes a non-starter. Enter the pick and place machine. This wonder of modern technology can drop all those microscopic components on your board in a fraction of the time it would take a human, and never needs to take a bathroom break. This week Chris Denney stopped by the Hack Chat to talk about these incredible machines and all the minutiae of turning your circuit board design into a finished product.

Chris is the Chief Technology Officer (CTO) of Worthington Assembly, a quick turn electronics manufacturer in South Deerfield, Massachusetts that has been building and shipping custom circuit boards since 1974. He knows a thing or two about PCB production, and looking to help junior and mid-level engineers create easier to manufacture designs, he started the “Pick, Place, Podcast” when COVID hit and in-person tours of the facility were no longer possible. Now he says he can tell when a board comes from a regular listener by how many of his tips make it into the design.

So what should you be doing to make sure your board assembly goes as smoothly as possible? Chris says a lot of it is pretty common sense stuff, like including clear polarity indicators, having a legible silkscreen, and the use of fiducial markers. But some of the tips might come as something of a surprise, such as his advice to stick with the classic green solder mask. While modern board houses might let you select from a rainbow of colors, the fact is that green is what most equipment has been historically designed to work with.

That black PCB might look slick, but can confuse older pick and place machines or conveyors which were designed with the reflectivity of the classic green PCB in mind. It also makes automated optical inspection (AOI) much more difficult, especially with smaller component packages. That said, other colors such as white and red are less of a problem and often just require some fine tuning of the equipment.

He also pulled back the curtain a bit on how the contract manufacturing (CM) world works. While many might have the impression that the PCB game has moved overseas, Chris says orders of less than 10,000 units are still largely handheld by domestic CMs to minimize turnaround time. He also notes that many assembly houses are supported almost entirely by a few key accounts, so while they may be juggling 50 customers, there’s usually just two or three “big fish” that provide 80% of their business. With such a tight-knit group, he cautions CMs can be a bit selective; so if a customer is difficult to work with they can easily find themselves on the short end of the stick.

While the Hack Chat is officially only scheduled for an hour, Chris hung out for closer to three, chatting with community members about everything and anything to do with electronic design and production. His knowledge and passion for the subject was readily apparent, and we’re glad he was able to make time in his schedule to join us.

Adafruit Hack Chat Helps You Copy That Floppy

February 4, 2022 by Tom Nardi 22 Comments

You might think the era of the 3.5 inch “floppy” disk is over, and of course, you’d be right. But when has that ever stopped hackers before? Just because these disks are no longer being manufactured doesn’t mean you can’t find them, or that the appropriate drives aren’t readily available. In fact, as [Ladyada] explained during this week’s Floppy Interfacing Hack Chat with Adafruit, the ongoing chip shortages mean its often easier and cheaper to track down old hardware like this than it is modern microcontrollers and other high-tech components.

What awaits the brave hacker that picks up a box of random floppies and a dusty old drive at the local thrift store? More than you might expect. As the Hack Chat goes on, it becomes increasingly obvious that these quaint pieces of antiquated technology can be rather difficult to work with. For one thing there are more formats out there than you’ve probably considered, and maddeningly, not all drives are able to read all types (even if they say they do). That means a disk which might seem like a dud on one drive could work perfectly fine in another, which is why the team at Adafruit recommend having a few on hand if you want to maximize your chances of success.

Now here comes the tricky part: unless you happen to have a 1990s vintage computer laying around, getting these drives hooked up is decidedly non-trivial. Which is why Adafruit have been researching how to interface the drives with modern microcontrollers. This includes the Adafruit_Floppy project, which aims to port the well known Greaseweazle and FluxEngine firmwares to affordable MCUs like the Raspberry Pi Pico. There’s also been promising developments with bringing native floppy support to CircuitPython, which would make reading these disks as easy as writing a few lines of code.

But wait, surely this is a solved problem? Why not just pick up a cheap USB floppy drive from the A to Z online retailer we all love to hate? Unfortunately, these gadgets are something of a mixed bag. [Ladyada] pulls one apart on camera to show that what you’re actually getting with one of these units is a new old stock laptop floppy drive hooked up to a dodgy purpose-built chip that connects to the original 26-pin flex cable and offers up a USB interface. That would be great, if it wasn’t for the fact that the chip is exceedingly selective about what kind of disks it will read. If you’re only worried about bog standard IBM-formatted disks they can work in a pinch, but like they say, you get what you pay for.

So is it all just academic? Is there really any reason to use a floppy disk in 2022? The fine folks at Adafruit would argue that the skills necessary to read usable data out of a stream of magnetic flux changes may very well come in handy in unexpected ways down the road. But even if not, there’s at least one good reason to cultivate the technology required to reliably read from these once ubiquitous storage devices: archiving the data stored on these disks before they invariably succumb to so-called “bit rot” and are potentially lost to history.

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