Vintage Electronics Hack Chat

Join us on Wednesday, January 25 at noon Pacific for the Vintage Electronics Hack Chat with Keri Szafir!

The world of the hardware hacker is filled with smells. The forbidden but enticing waft of solder smoke, the acrid bite of the Magic Blue Smoke, the heady aroma of freshly greased gears, the unmistakable smell of hot metal — they all tell a story, sometimes good, sometimes bad.

But the smell inside a piece of vintage electronics? Now that’s a complicated story indeed. It might be the wax of the old capacitors, the resinous scent of well-baked resistors, the enameled wire in transformers, or just the smell of the hot glass of the vacuum tubes. Whatever it is, once you smell it, you’ll never forget it

join-hack-chatFor some of us, that first whiff starts a lifelong passion for vintage gear. Keri Szafir knows quite well what it’s like to be bitten by the vintage bug, so much so that she goes by “The Vacuum Tube Witch” over on her YouTube channel. Her projects include repairs and restorations of vintage amps and radios, and even new builds with old tubes. She’ll stop by the Hack Chat to talk about vintage electronics, tube hoarding collecting, and even her new interest in retro display technologies. Where there’s a tube, there’s a way!

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, January 25 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

Machining With Electricity Explored In The Hack Chat

As a Hackaday reader, it’s safe to assume you’ve got a better than average understanding of electricity. There’s also an excellent chance you’re familiar with machining, and may even have a lathe or old mill in the workshop. But combining the two, and actually machining a piece of metal with electricity, isn’t something that many home gamers can boast first-hand experience with.

Daniel Herrington

Of course, that doesn’t mean there isn’t an interest. To help answer the burning (or at least, sparking) questions from the community, CEO and founder of Voxel Innovations Daniel Herrington stopped by this week’s Hack Chat to talk about the cutting edge of both electric discharge machining (EDM) and the closely related field of electrochemical machining (ECM). While his company uses the technology to produce components at incredible scales, Daniel got his start tinkering in the garage like so many of us, enabling him to provide both a professional and hobbyist prospective on the technologies.

Naturally, the first big question to be addressed was the difference between EDM and ECM. Put simply, electric discharge machining uses high-voltage to literally blast away material from the workpiece. The resulting finish is generally rough, and progress through the material tends to be slow, but it’s relatively simple to implement.

In contrast electrochemical machining could be thought of as a sort of reverse electroplating process, as the material being removed from the workpiece is dissolved and transferred to the cathode — though in practice the flow of pressurized electrolyte keeps it from actually plating the negatively charged tool. ECM is a faster process than EDM and allows for an exceptionally smooth surface finish, but is considerably more challenging from a technical perspective. Continue reading “Machining With Electricity Explored In The Hack Chat”

Machining With Electricity Hack Chat

Join us on Wednesday, January 18 at noon Pacific for the Machining with Electricity Hack Chat with Daniel Herrington!

With few exceptions, metalworking has largely been about making chips, and finding something hard enough and tough enough to cut those chips has always been the challenge. Whether it’s high-speed steel, tungsten carbide, or even little chunks of rocks like garnet or diamond, cutting metal has always used a mechanical interaction between tool and stock, often with spectacular results.

But then, some bright bulb somewhere realized that electricity could be used to remove metal from a workpiece in a controlled fashion. Whether it’s using electric sparks to erode metal — electric discharge machining (EDM) — or using what amounts to electroplating in reverse — electrochemical machining (ECM) — electrical machining methods have made previously impossible operations commonplace.

join-hack-chatWhile the technology behind ExM isn’t really that popular in the hobby machine shop yet, a lot of the equipment needed and the methods to make it all work are conceivably DIY-able. But the first step toward that is understanding how it all works, and we’re lucky enough to have Daniel Herrington stop by the Hack Chat to help us out with that. Daniel is CEO and founder of Voxel Innovations, a company that’s on the cutting edge of electrochemical machining with its pulsed ECM technology. There’s a lot to unpack, so make sure you stop by so we can all get up to speed on what’s up with using electricity to do the machining.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, January 18 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

Battery Engineering Hack Chat Gets Charged Up

Turn the clock back a couple of decades, and the only time the average person would have given much thought to batteries was when the power would go out, and they suddenly needed to juice up their flashlight or portable radio.  But today, high-capacity batteries have become part and parcel to our increasingly digital lifestyle. In fact, there’s an excellent chance the device your reading this on is currently running on battery power, or at least, is capable of it.

So let’s get to know batteries better. What’s the chemical process that allows them to work? For that matter, what even is a battery in the first place?

It’s these questions, and more, that made up this week’s Battery Engineering Hack Chat with Dave Sopchak. Our last Hack Chat of 2022 ended up being one of the longest in recent memory, with the conversation starting over an hour before the scheduled kickoff and running another half hour beyond when emcee Dan Maloney officially made his closing remarks. Not bad for a topic that so often gets taken for granted.

Continue reading “Battery Engineering Hack Chat Gets Charged Up”

Battery Engineering Hack Chat

Join us on Wednesday, December 14 at noon Pacific for the Battery Engineering Hack Chat with Dave Sopchak!

Of all the things driving technology forward, you’d have to say that the ability of chip makers to squeeze more complex circuits than ever onto silicon has to rank right up there. And while that’s no doubt true, it only tells a part of the story. For our money, though, the advancements in battery technology over the last 30 years or so are the real champ, because without compact, cheap, energy-dense batteries, almost none of the cool stuff we see today, from smartphones to electric vehicles, would be practical.

Battery technology has come a long way from the days when carbon-zinc and nickel-cadmium cells were kings. New chemistries, better materials and methods, and engineering improvements have all contributed to incredibly powerful, incredibly compact batteries that make applications nobody could have thought of just a few decades ago possible.

join-hack-chatDave Sopchak has been in the thick of battery engineering since taking a doctorate in electrochemistry from Case Western Reserve. Since then he has worked at several fuel cell start-ups, and is now working on a lithium-air battery that sounds really interesting. We’ve asked him to help us wrap up the 2022 Hack Chat series with a discussion on battery engineering, with a focus on upcoming technologies and advancements that could really put some power in your pocket.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, December 14 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

The Amateur Rocketry Hack Chat Reaches For The Stars

Hackaday has been around long enough to see incredible changes in what’s possible at the hobbyist level. The tools, techniques, and materials available today border on science-fiction compared to what the average individual had access to even just a decade ago. On a day to day basis, that’s manifested itself as increasingly elaborate electronic projects that in many cases bear little resemblance to the cobbled together gadgets which graced these pages in the early 2000s.

Kip Daugirdas

But these gains aren’t limited to our normal niche — hobbyists of all walks have been pushing their respective envelopes. Take for example the successful launch of MESOS, a homebuilt reusable multi-stage rocket, to the very edge of the Kármán line. It was designed and built by amateur rocket enthusiast Kip Daugirdas over the course of several years, and if all goes to plan, will take flight once again this summer with improved hardware that just might help it cross the internationally recognized 100 kilometer boundary that marks the edge of space.

We were fortunate enough to have Kip stop by the Hack Chat this week to talk all things rocketry, and the result was a predictably lively conversation. Many in our community have a fascination with spaceflight, and even though MESOS might not technically have made it that far yet (there’s some debate depending on who’s definition you want to use), it’s certainly close enough to get our imaginations running wild.

Continue reading “The Amateur Rocketry Hack Chat Reaches For The Stars”

Amateur Rocketry Hack Chat

Join us on Wednesday, November 30 at noon Pacific for the Amateur Rocketry Hack Chat with Kip Daugirdas!

This might be going out on a limb, but it seems like most of us probably fooled around with model rockets when we were younger. Those fantastic Estes kits were great fun to put together, and launching them was always a big neighborhood event, and one of the few that could make even the coolest of the cool kids pay attention to the nerds, if only for a little while. Launch day had it all — a slight element of danger, the rotten egg stink of spent propellant, a rocket gently floating back to Earth from a dizzying height of 100 meters, and the inevitable tree-climbing party to retrieve a lost rocket.

join-hack-chatBut while model rocketry is fun, it doesn’t scale up very well. If you want to reach the edge of space, you’re going to need to make the leap across the border to amateur rocketry. That’s where the big kids play, with real engineering needed to produce and control the forces required to reach altitudes of 100 km or more. Kip Daugirdas has made that leap, building rockets capable of almost getting to the Kármán line. It’s not easy — there was plenty of design work, static engine testing, and loads of test flights leading up to it, and surely more to come. Kip will stop by the Hack Chat to help us understand what’s needed to press the edge of space, and hopefully share his plans for going all the way.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, November 30 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.