Developed On Hackaday – It’s A Badge. No, It’s The HaDge

October 26, 2015 by Anool Mahidharia 14 Comments

Sometime back, we announced start of a new project under the “Developed on Hackaday” series – a Badge for the Hackaday community. At its core, this badge is a single node in an Internet of Badges. At every event this badge is deployed at, a Hackaday Sub-Etha mesh network will be created, and each badge will be able to transmit and receive messages from other badge wearers. There are plans for an Sub-Etha to Internet gateway, so even if badge wearers are on the other side of the world, they’re still connected through the HaDge network.

Things have been moving along quickly, so I thought of doing a quick round-up and share progress with the community. First off, it has a name. HaDge, as in HackaDay Badge. Our objectives up until now were to set up a team, name the project, set up repositories and lock down on a working bill of materials. Within a few weeks, we’ve got all of that tied down. The HaDge group chat channel has been super active, and everyone’s been pitching in with ideas and suggestions. A spreadsheet seemed like a good idea – it let everyone add in their suggestions regarding candidate parts, create a feature list and then talk about it on the channel.

We realized early on that building the hardware is going to take some time. So in the interim, we need a dev kit platform to get in to the hands of the software developers so they can start working on the smarts that will power the HaDge. [Michele Perla] had already built JACK (Just another Cortex kit) – a development kit powered by the Atmel SAM D21. It’s pretty bare bone with just the bare minimum of parts to make it work while keeping an eye on reliability. The microcontroller+radio on the HaDge is the Atmel SAM R21 – a close relative of the D21, so it made sense to respin the JACK and create HACK (Hackaday Cortex kit) – a development kit powered by the Atmel SAM R21 that is going to be used as the core of the HaDge. [Michele] has worked hard single-handedly to complete the design and it is now ready to go for PCB fabrication soon. We are just awaiting some feedback and review of the Antenna part of the design. None of us on the hardware team have a strong RF-fu so we don’t want to make an avoidable mistake. If you’d like to review and help vet the HACK design, grab the design files from the github repo and let us know.

Once HACK board layout is cleared for fabrication, we’ll work on building kits that can be sent out to the software folks. We will also be working on porting the HACK design in to KiCad and this is something I have already stared work on. I started by using the neat Eagle2KiCad conversion tool by [LachlanA]. It’s not perfect, but it does reduce the work involved in porting over from Eagle to Kicad. Once that is done, hardware development for the actual HaDge will see some progress – keep a watch on the project page.

Hackaday’s DC Meetup And Workshops

September 14, 2015 by Mike Szczys 6 Comments

Washington DC has a vibrant hardware hacking community and it was out in force on Saturday night. We had over one hundred people through the door at Nova Labs in Reston, Virginia (DC metro area). This sleek and spacious hackerspace opened their doors for a Hackaday Meetup as part of a weekend packed full of activities.

Blinky hats

RPi powered Teletype machine

LED marquee cube

Wyolum reaction time game

The building that Nova Labs moved into not too long ago is a really well-suited area for a Hackerspace. The front half of the building includes a huge open space which has plenty of room for people to set up the hardware they wanted to show off. The back has a full woodshop, machine shop, and more, with classrooms and conference rooms in between.

Above are a set of hats with addressible LED strings wrapped around them which [ArsenioDev] brought along with him. Several members of the Wyolum team are involved with Nova Labs and they were showing off some LED matrix-based projects like the marquee cube and a 3-player reaction time game. And clacking away all night long is a vintage teletype machine that [Bob Coggeshall] fixed and connected to a Raspberry Pi.

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Saturday In Washington DC: Hackaday Meetup

September 9, 2015 by Mike Szczys 3 Comments

If you’re in the DC area, clear your schedule this Saturday night. Hackaday is hosting a Meetup at Nova Labs starting at 6pm. All you need to do is let us know you’re planning to attend.

The Reston, Virginia hackerspace is minutes away from Dulles airport. If you haven’t stopped by the hackerspace since they moved this is a great chance to see the new location. Bring along any hardware you’re working on. You can give a lightning talk about it, or just show it off casually while enjoying some food and beverage. Several members of the Hackaday crew will be on hand: [Anool Mahidharia] will be in town presenting a weekend-long workshop on PCB design using KiCAD. [Mike], [Brian], and [Sophi] will join him for the meetup on Saturday evening. For more details on what is going down that weekend take a look at the original announcement post. See you soon!

Hackaday Prize Worldwide: Washington DC

September 3, 2015 by Mike Szczys 4 Comments

Join us for a Meetup on Saturday, September 12th near Washington DC. The Hackaday Crew is headed out to the DC area a week from Saturday and we want to hang out with you. We’ll be hosting a meetup at Nova Labs hackerspace in Reston, Virgina which is on the Northwest side of DC.

We’ll get things rolling at 6pm on Saturday, September 12. The event includes a few lightning talks, some food and drink, and a lot of socializing. This is free to all but you do need to RSVP to let us know you’re coming. We want you to bring a hack to show off. We love to see what people are working on no matter the level of complexity or stage of completion.

This all started when [Anool Mahidharia] mentioned that he’d be at Nova Labs on September 11-13 to lead a KiCAD PCB design workshop. This 2.5 day boot-camp starts with installing the Open Source EDA software on your laptop and ends when you have a completed PCB design ready to be submitted to a board fab. There is a charge for the workshop and attendance is limited so if you’re interested in it you should sign up now. Our events page is a good collection of information on both events as well as directions to get to Nova Labs.

The workshop is being organized by our friend [Bob Coggeshall] who we first met (and interviewed about his work on the Linux ‘sudo’ command) back in 2014 at Bay Area Maker Faire. Since then, [Brian Benchoff] swung by and visited [Bob] to talk about his company Small Batch Assembly and to tour Nova Labs. He will be conducting his own surface mount soldering workshop, will speak about Design For Manufacturing, and will show his Pick and Place machine during the weekend.

It will be fun to visit with [Bob] and to meet everyone who can make it to the Saturday evening meetup. So far [Mike Szczys], [Brian Benchoff], and [Sophi Kravitz] are all planning to be there. [Anool Mahidharia] will of course be there since he’s leading the workshop. The following weekend [Anool] and [Brian] will both be headed to Philadelphia for the 2015 Open Hardware Summit for which Hackaday is a proud sponsor. [Matt Berggren] and [Amber Cunningham] will both be at OSH as well, talking all things Tindie.

Hackaday Prize Worldwide : New Delhi Kicad + Show And Tell

July 28, 2015 by Anool Mahidharia 5 Comments

While Mumbai and Bengaluru have an active and large hacker community, New Delhi, India’s capital, seems to have leapfrogged ahead when it comes to hackerspaces – four at last count. So when the latest one in town, Maker’s Asylum, opened it’s doors last month, we decided to put together a hacker congregation to bring the community together and introduce them to the Hackaday Prize. Having already done Hackaday Prize bring-a-hack events in Mumbai and Bengaluru, we thought of doing something more substantial – a day long KiCad EDA workshop followed in the evening by a Show-n-Tell brag show.

Hackaday’s [Matt Berggren a.k.a. @technolomaniac] has done a couple of “Design a PCB from zero to WiFi with Hackaday!” Eagle EDA workshops recently. He designed a simple breakout board that allowed connecting an ESP-01 module to the USB port via an USB-UART cable with level conversion, pull up resistors and push button switches to make it easy to program. We had a slightly delayed start, so I quickly rushed through the awesome presentation that [Matt] has prepared, running through the “What is a PCB?” section and skipping the rest. We also discussed a couple of candidate designs for the day’s workshop – a pair of ATtiny line following robots, a simple Attiny SmartLED controller, but eventually, everyone got excited when I mentioned “ESP-8266” !

“What is a PCB?”

KiCad workshop

A helping hand

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A Automated Optical Inspection machine, inspecting the USB Armory board

Meet The Machines That Build Complex PCBs

March 31, 2015 by Eric Evenchick 12 Comments

You can etch a simple PCB at home with a few chemicals and some patience. However, once you get to multilayer boards, you’re going to want to pay someone to do the dirty work.

The folks behind the USB Armory project visited the factories that build their 6 layer PCB and assemble their final product. Then they posted a full walkthrough of the machines used in the manufacturing process.

The boards start out as layers of copper laminates. Each one is etched by applying a film, using a laser to print the design from a Gerber file, and etching away the unwanted copper in a solution. Then the copper and fibreglass prepreg sandwich is bonded together with epoxy and a big press.

Bonded boards then get drilled for vias, run through plating and solder mask processes and finally plated using an Electroless Nickel Immersion Gold (ENIG) process to give them that shiny gold finish. These completed boards are shipped off to another company, where a pick and place followed by reflow soldering mounts all the components to the board. An X-Ray is used to verify that the BGA parts are soldered correctly.

The walkthrough gives a detailed explanation of the process. It shows us the machines that create products we rely on daily, but never get to see.

Putting New Into The Old – A Phonograph Upgrade.

March 17, 2015 by Anool Mahidharia 28 Comments

[smellsofbikes] recently came into possession of a 1970’s “stereo radio phonograph” cabinet consisting of a vinyl record player, AM and FM radio, and eight track tape player. The radio worked, the turntable didn’t sound too nice, and the tape player didn’t work at all. A new needle fixed the turntable, but the eight-track was in bad shape. So he replaced the tape player with a BeagleBoneBlack which plays streaming internet radio.

Hopefully, this fix is temporary, since he has carefully disconnected the tape player connections in the hope of fixing it soon. The swap out involved a fair bit of engineering, so he’s split his build log into several bite sized chunks. The first step was to set up the BBB, upgrade it and add in all the network and audio related stuff. Audio on the BBB is available only via the HDMI port, but [smellsofbikes] had a USB soundcard handy, so the next step was setting that up. He installed mpg321 – the command line mp3 player and set it up to play music streaming from somafm. Next up was getting some scripts and programs to run automatically during system bootup. The final part of the setup was adding a WiFi router as a repeater connected to the BBB via an ethernet cable. He could have used a tiny WiFi USB dongle, but he already had the router lying around, and he wanted to dedicate USB to audio functions alone, and use the Ethernet port for Internet.

He then worked on identifying the wires that go from the tape player to the amplifier, spliced them, and hooked them up to the audio sound card on the BBB. With this done, the upgrade was more or less complete – the system played streaming music and stations could be switched remotely (via SSH to BBB). [smellsofbikes] reckoned it would be nice to use the existing controls in the phonograph cabinet to control the internet streaming music, instead of controlling it via a remote computer. The cabinet had 4 indicator lamps that indicated which track was being played and a button to switch between tracks. He removed the old indicator panel and put in a fresh PCB, designed in KiCad and cut on his LPKF circuit board plotter. An aluminum knob machined out of hex bar-stock works as the new track change button. At this point, he called it a wrap. The BBB and Asus router go inside the cabinet, and the old (non-functional) tape player is put in place. Quite an interesting build, and we look forward to when he actually gets the tape player working. [Alan Martin], aka “The Most Interesting Engineer In The World” has told him that “it is a moral imperative that you repair the eight-track and get it working”. [Alan] has promised to send [smellsofbikes] a suitcase full of brand new, still in their plastic wrappers, eight-track tapes when he gets it working.