These Tips Make Assembling A Few Hundred PCBs Easier

September 12, 2019 by Donald Papp 7 Comments

There are a few common lessons that get repeated by anyone who takes on the task of assembling a few hundred PCBs, but there are also unique insights to be had. [DominoTree] shared his takeaways after making a couple hundred electronic badges for DEFCON 26 (that’s the one before the one that just wrapped up, if anyone’s keeping track.) [DominoTree] assembled over 200 Telephreak badges and by the end of it he had quite a list of improvements he wished he had made during the design phase.

Some tips are clearly sensible, such as adding proper debug and programming interfaces, or baking an efficient test cycle into the firmware. Others are not quite so obvious, for example “add a few holes to your board.” Holes can be useful in unexpected ways and cost essentially zero. Even if the board isn’t going to be mounted to anything, a few holes can provide a way to attach jigs or other hardware like test fixtures.

[DominoTree] ended up having to attach multiple jumper wires to reprogram boards after assembly, and assures us that “doing this a bunch of times really sucked.”

Other advice is more generic but no less important, as with “eliminate as many steps as possible.” Almost anything adds up to a significant chunk of time when repeated hundreds of times. To the basement hacker, something such as pre-cut and pre-tinned wires might seem like a shameful indulgence. But cutting, stripping, tinning, then hand-soldering a wire adds up to significant time and effort by iteration number four hundred (that’s two power wires per badge) even if one isn’t staring down a looming deadline.

[DominoTree] also followed up with additional advice on making assembly easier. Our own [Brian Benchoff] has also shared his observations on the experience of developing and assembling a large number of Hackaday Superconference badges, including what it took to keep things moving along when inevitable problems surfaced.

You don’t need to be making batches of hundreds for these lessons to pay off, so keep them in mind and practice them on your next project.

The Numberwang Badge Brought Cheer To CCCamp 2019

September 2, 2019 by Jenny List 9 Comments

While wandering through CCCamp last weekend, in between episodes of forcing Marmite on the unwary, I ran into the well-known Hackaday.io user [Prof. Fartsparkle]. In a last-minute sprint leading up to the con he built himself the Numberwang badge to join in the colorful after-dark festivities with beautiful board artwork and remarkably enjoyable backlit LED display.

The Numberwang badge itself is a clone of the Adafruit Itsy Bitsy sporting an ATSAMD21G18 CPU and running CircuitPython. It has an LED strip on the reverse shining through the bare FR4 as a diffuser, and the Numberwang effect of selecting random numbers is achieved by a host of random touchable numbers sprinkled across its front. For something he freely admits was a last minute project, we think he’s done a pretty good job!

For those mystified by Numberwang, it is a fictional gameshow from a BBC TV comedy programme that involves contestants answering the quizmaster with random numbers. It joins a rich tradition of such hilarious nonsense, and has as a result become cult television.

If you’re really getting into Numberwang, don’t forget that it’s inspired a programming language.

Continue reading “The Numberwang Badge Brought Cheer To CCCamp 2019” →

After The Con: Da Bomb Badge Post Mortem

September 2, 2019 by Jenny List No comments

We’ve reported on the world of electronic badges here at Hackaday since their earliest origins in [Joe Grand]’s work for DEF CON 14 in 2006. In that time we’ve seen an astonishing variety of creations, covering everything from abstract artwork to pure functionality in a wearable device. But it’s not been quite so often that we’ve looked at the other side of the BadgeLife coin, so it’s fascinating to read [John Adams]’ account of the work that went into the production of this year’s 500-piece run of the Da Bomb DEF CON indie badge.

In it, [John] goes over scheduling worries, component sourcing issues, PCB assembly delays, and an in-depth look into the finances of such a project. In case anyone is tempted to look at Badgelife as the route to millions, it rapidly becomes apparent that simply not losing too much money is sometimes the best that can be hoped for. There were a few design problems, one of them being that the SAO I2C bus was shared with the LED controller, resulting in some SAOs compatibility issues. In particular the AND!XOR DOOM SAO had its EEPROM erased, creating something of a headache for the team.

A surprise comes in the distribution: obviously shipping is expensive, so you’d think badge pick-ups at the con would be straightforward alternative. Unfortunately, they became something of a millstone in practice, and organising them was a Herculean task. Astoundingly, some paying customers didn’t bother turn up for their badges. Which was especially infuriating since the team lost valuable conference time waiting for them.

Some of you are BadgeLife creators and will nod sagely at this. Still more of you will wish you were BadgeLife creators and find it a useful primer. For everyone else it’s a fascinating read, and maybe makes us appreciate our badges a bit more.

The images may have departed, but just to return to the origins of BadgeLife, here’s our coverage of that first [Joe Grand] badge.

Hands-On: CCCamp2019 Badge Is A Sensor Playground Not To Be Mistaken For A Watch

August 29, 2019 by Mike Szczys 19 Comments

Last weekend 5,000 people congregated in a field north of Berlin to camp in a meticulously-organized, hot and dusty wonderland. The optional, yet official, badge for the 2019 Chaos Communication Camp was a bit tardy to proliferate through the masses as the badge team continued assembly while the camp raged around them. But as each badge came to life, the blinkies that blossomed each dusk became even more joyful as thousands strapped on their card10s.

Yet you shouldn’t be fooled, that’s no watch… in fact the timekeeping is a tacked-on afterthought. Sure you wear it on your wrist, but two electrocardiogram (ECG) sensors for monitoring heart health are your first hint at the snoring dragon packed inside this mild-mannered form-factor. The chips in question are the MAX30001 and the MAX86150 (whose primary role is as a pulse sensor but also does ECG). We have high-res ADCs just waiting to be misused and the developers ran with that, reserving some of the extra pins on the USB-C connector for external devices.

There was a 10€ kit on offer that let you solder up some electrode pads (those white circles with gel and a snap for a solid interface with your body’s electrical signals) to a sacrificial USB-C cable. Remember, all an ECG is doing is measuring electrical impulses, and you can choose how to react to them. During the workshop, one of the badge devs placed the pads on his temples and used the card10 badge to sense left/right eye movement. Wicked! But there are a lot more sensors waiting for you on these two little PCBs.

Continue reading “Hands-On: CCCamp2019 Badge Is A Sensor Playground Not To Be Mistaken For A Watch” →

Hello: A Mini Badge For CCCamp

August 21, 2019 by Jenny List 1 Comment

Badgelife culture is our community’s very own art form, with a plethora of designs coming forth featuring stunning artwork, impressive hardware, and clever software tricks. But sometimes a badge doesn’t need a brace of LEDs or a meme-inspired appearance to be a success, it just needs to be very good at what it does.

A perfect example is [Gavan Fantom]’s Hello mini badge. The hardware is fairly straightforward, it’s just a small square PCB sporting a LPC1115 microcontroller, 8Mb Flash chip, piezo speaker, and an OLED display. Its functionality is pretty simple as well, in that it exists to display text, images, or short animations. But the badge hides a very well-executed firmware that provides a serial terminal and zmodem file upload capability as well as an on-device interface via a small joystick. Power comes from a 500 mAh lithium-polymer cell, for which the badge integrates the usual charger and power management hardware.

There’s a variety of possibilities for the badge, but we’d guess that most owners will simply use it to display their name with perhaps a little animation. A bit of nifty processing of some video could perhaps get something approaching watchable video on it though, opening up the entertaining possibility of displaying demos or other video content.

[Gavan] will have some of the Hello badges at the upcoming CCCamp hacker camp in Germany if you’re interested, and should be easy enough to find in the EMF village.

CampZone 2019 Badge Is Begging To Become A Huge Billboard

July 25, 2019 by Jenny List 16 Comments

What has 256 full-colour LEDs, everyone’s favorite Lithium battery form factor, wireless connectivity, and hangs around your neck? It’s the CampZone 2019 badge that turns all attendees into a really fun billboard — but can the attendees hack themselves into one massive display?

One of Europe’s larger events for the gaming community, CampZone is hosted in Netherlands and runs from July 26th to August 5th. It’s a typical large summer camp, and caters for those who intersect gaming and hacking with HackZone, a decent sized hacker camp within a camp. I’ve been fortunate enough to get my hands on a CampZone 2019 badge, dubbed the I-Pane, let’s take a look at what they managed to pack into this electronic conference badge.

Continue reading “CampZone 2019 Badge Is Begging To Become A Huge Billboard” →

Live Apollo 11 Transcript On EInk Display

July 18, 2019 by Tom Nardi 1 Comment

There are few moments in history that have ever been recorded in more detail or analyzed as thoroughly as the Apollo 11 mission to the Moon. Getting three men to our nearest celestial neighbor and back in one piece took a lot of careful planning, and recording every moment of their journey was critical to making sure things were going smoothly. As we celebrate the 50th anniversary of man’s first steps off our world, these records give us a way to virtually tag along with Armstrong, Aldrin, and Collins.

As part of the 50th anniversary festivities at the Parkes Radio Telescope in Australia, [Andrew] created a badge that would let him wear a little piece of Apollo 11. Using an ESP32 and an eInk screen, it replays the mission transcript between the crew and ground control in real-time. It’s a unique way to experience the mission made possible by that meticulous data collection that’s a hallmark of the National Aeronautics and Space Administration.

[Andrew] was inspired by the “Apollo 11 In Real Time” website, but rather than pulling the content from the Internet, he’s loaded the mission transcripts onto the ESP32’s SPIFFS filesystem as a CSV file. Not that the badge is completely offline, it does need to connect to the Internet (via a hotspot on his phone) so it can keep its internal clock synchronized with NTP. Keeping everything local does reduce power consumption compared to streaming it from the Internet, but he admits that otherwise he didn’t give much thought to energy efficiency and there’s definitely some room for improvement.

The LILYGO TTGO board he’s using combines the ESP32 with a 2.13 inch eInk display, in a formfactor not unlike the Badgy we’ve covered previously. He was able to find a STL for a 3D printed case on Thingiverse which he modified to fit a battery. Unfortunately the original model was released under a license that prevents him from distributing his modified version, but it doesn’t sound too difficult to replicate if you’re interested in building your own running ticker of humanity’s greatest adventure.