WiFiWart Linux Pentesting Device Gets First PCBs

July 3, 2021 by Tom Nardi 15 Comments

When we last checked in on the WiFiWart, an ambitious project to scratch-build a Linux powered penetration testing drop box small enough to be disguised as a standard phone charger, it was still in the early planning phases. In fact, the whole thing was little more than an idea. But we had a hunch that [Walker] was tenacious enough see the project through to reality, and now less than two months later, we’re happy to report that not only have the first prototype PCBs been assembled, but a community of like minded individuals is being built up around this exciting open source project.

Now before you get too excited, we should probably say that the prototypes didn’t actually work. Even worse, the precious Magic Smoke was released from the board’s Allwinner A33 ARM SoC when a pin only rated for 2.75 V was inadvertently fed 3.3 V. The culprit? Somehow [Walker] says he mistakenly ordered a 3.3 V regulator even though he had the appropriate 2.5 V model down in the Bill of Materials. A bummer to be sure, but that’s what prototypes are for.

Even though [Walker] wasn’t able to fire the board up, the fact that they even got produced shows just how much progress has been made in a relatively short amount of time. A lot of thought went into how the 1 GB DDR3 RAM would get connected to the A33, which includes a brief overview of how you do automatic trace length matching in KiCad. He’s also locked in component selections, such as the RTL8188CUS WiFi module, that were still being contemplated as of our last update.

Multiple boards make better use of vertical space.

Towards the end of the post, he even discusses the ultimate layout of the board, as the one he’s currently working on is just a functional prototype and would never actually fit inside of a phone charger. It sounds like the plan is to make use of the vertical real estate within the plastic enclosure of the charger, rather than trying to cram everything into a two dimensional design.

Want to get in on the fun, or just stay updated as [Walker] embarks on this epic journey? Perhaps you’d be interested in joining the recently formed Open Source Security Hardware Discord server he’s spun up. Whether you’ve got input on the design, or just want to hang out and watch the WiFiWart get developed, we’re sure he’d be happy to have you stop by.

The first post about this project got quite a response from Hackaday readers, and for good reason. While many in the hacking and making scene only have a passing interest in the security side of things, we all love our little little Linux boards. Especially ones that are being developed in the open.

Surf’s Up, A Styrofoam Ball Rides The Waves To Create A Volumetric Display

March 19, 2021 by Michael Shaub 22 Comments

We are big fans of POV displays, particularly ones that move into 3D. To do so, they need to move even faster than their 2D cousins. [danfoisy] built a volumetric display that doesn’t move LEDs or any other digital display through space, or project light onto a moving surface. All that moves here is a bead of styrofoam and does so at up to 1 meter per second. Having low mass certainly helps when trying to hit the brakes, but we’re getting ahead of ourselves.

[danfoisy] and son built an acoustic levitator kit from [PhysicsGirl] which inspired the youngster’s science fair project on sound. See the video by [PhysicsGirl] for an explanation of levitation in a standing wave. [danfoisy] happened upon a paper in the Journal Nature about a volumetric display that expanded this one-dimensional standing wave into three dimensions. The paper described using a phased array of ultrasonic transducers, each with a 40 kHz waveform.

After reading the paper and determining how to recreate the experiment, [danfoisy] built a 2D simulation and then another in 3D to validate the approach. We are impressed with the level of physics and programming on display, and that the same code carried through to the build.

[danfoisy] didn’t stop with the simulations, designing and building control boards for each ~~100 x 100~~ 10 x 10 grid of transducers. Each grid is driven by 2 Intel Cyclone FPGAs and all are fed 3D shapes by a Raspberry Pi Zero W. The volume of the display is 100 mm x 100 mm x 145mm and the positioning of the foam ball is accurate down to .01 mm though currently there is considerable distortion in the positioning.

Check out the video after the break to see the process of simulating, designing, and testing the display. There are a number of tips along the way, including how to test for the polarity of the transducers and the use of a Python script to place the grids of transducers and drivers in KiCad.

Continue reading “Surf’s Up, A Styrofoam Ball Rides The Waves To Create A Volumetric Display” →

chadaustin's sculpt keyboard test pads wired to protonC

Tether Tames Temperamental Typing

March 18, 2021 by Michael Shaub 6 Comments

[chadaustin] has a favorite keyboard with a great ergonomic shape, key travel distance, and size, but after switching to Windows 10, the wireless connection introduced a terrible delay. Worse yet, the receiver is notoriously susceptible to interference from USB 3.0 hubs. To provide 128-bit AES encryption, the receiver is paired with the keyboard at the factory and cannot be replaced. If you lose that, you gain a highly ergonomic paper-weight. The solution for [chadaustin] was tethering the keyboard and receive several crash-courses in hardware hacking along the way. As evidenced by the responses to this project on ycombinator, many long-time fans of the Microsoft Sculpt Ergonomic Keyboard, introduced in 2013, suffer similar issues.

chadaustin's sculpt keyboard USB board layout — KiCad USB controller board layout

We really appreciate that [chadaustin] took an incremental approach, tackling one problem at a time and getting help from others along the way for first attempts at many complex steps. The proof-of-concept involved hand-soldering each lead from the keyboard matrix’s test pads to a QMK Proton C, which worked but couldn’t fit inside the keyboard’s case. For a more permanent and tidy solution, [chadaustin] tried a ribbon-cable breakout board and other microcontrollers, but none of those were compact enough to fit inside the case either. This required a custom PCB, another first for [chadaustin].

After a one-day intro to KiCad, [chadaustin] dug into the datasheets, completed a schematic for the board, and generously shared the process of choosing components and creating the layout. [chadaustin] ordered a board and found the mounting holes’ placement needed to be shifted.

With the full matrix mapped by [johnmilkspill], flashing QMK onto the AT90USB1286 controller went fairly smoothly. [chadaustin] chose to map both sides of the split spacebar back to the space key but did add a feature by repurposing the battery indicator LED to Caps Lock. And the results?

chadaustin's sculpt keyboard USB controller fit into case — USB controller fits into the plastic case, wires added to ISP for bootloader button

According to testing done with Is It Snappy?, the latency dropped from the wireless 78 ms down to 65 ms over USB. More importantly, this latency is now consistent, unaffected by USB hubs, and there is no receiver to lose. Of course, [chadaustin] has ideas for future improvement, including regaining the multimedia function keys, as these kinds of hacks are never really done; they are just in the current revision. No word on the fate of the detached number pad, but that likely needs its own tether and is a project for another day.

Thanks for the tip [Linus Söderlind]

An Anti-Tamper Mesh Plugin For KiCad

March 14, 2021 by Mike Szczys 31 Comments

Physical access to electronics generally means all bets are off when it comes to information security. But in special cases this is just unacceptable and a better solution must be found. Consider the encryption keys used by point of sale machines. To protect them, the devices incorporate anti-tamper mechanisms that will wipe the keys from memory if the device is opened. One such technique is to use a mesh of traces on a circuit board that are monitored for any changes in resistance or capacitance. [Sebastian Götte] has been researching in this area and wrote a KiCad plugin to automatically generate tamper-detection mesh.

The idea is pretty simple, place traces very close to one another and it makes it impossible to drill into the case of a device without upsetting the apple cart. There are other uses as well, such as embedding them in adhesives that destroy the traces when pried apart. For [Sebastian’s] experiments he’s sticking with PCBs because of the ease of manufacture. His plugin lays down a footprint that has four pads to begin and end two loops in the mesh. The plugin looks for an outline to fence in the area, then uses a space filling curve to generate the path. This proof of concept works, but it sounds like there are some quirks that can crash KiCad. Consider taking a look at the code if you have the expertise to help make it more stable.

We’ve seen these anti-tamper meshes in practice in the VeriFone payment terminal that [Tom Nardi] tore down a couple of years ago. The approach that [Sabastian] took with the plugin actually produces a more complex mesh than was in use there as it only really used vertical lines for the traces.

Peek Into This Synth’s Great Design (And Abandoned Features)

March 9, 2021 by Donald Papp 30 Comments

[Tommy]’s POLY555 is an analog, 20-note polyphonic synthesizer that makes heavy use of 3D printing and shows off some clever design. The POLY555, as well as [Tommy]’s earlier synth designs, are based around the 555 timer. But one 555 is one oscillator, which means only one note can be played at a time. To make the POLY555 polyphonic, [Tommy] took things to their logical extreme and simply added multiple 555s, expanding the capabilities while keeping the classic 555 synth heritage.

The real gem here is [Tommy]’s writeup. In it, he explains the various design choices and improvements that went into the POLY555, not just as an instrument, but as a kit intended to be produced and easy to assemble. Good DFM (Design For Manufacturability) takes time and effort, but pays off big time even for things made in relatively small quantities. Anything that reduces complexity, eliminates steps, or improves reliability is a change worth investigating.

For example, the volume wheel is not a thumbwheel pot. It is actually a 3D-printed piece attached to the same potentiometer that the 555s use for tuning; meaning one less part to keep track of in the bill of materials. It’s all a gold mine of tips for anyone looking at making more than just a handful of something, and a peek into the hard work that goes into designing something to be produced. [Tommy] even has a short section dedicated to abandoned or rejected ideas that didn’t make the cut, which is educational in itself. Want more? Good news! This isn’t the first time we’ve been delighted with [Tommy]’s prototyping and design discussions.

POLY555’s design files (OpenSCAD for enclosure and parts, and KiCad for schematic and PCB) as well as assembly guide are all available on GitHub, and STL files can be found on Thingiverse. [Tommy] sells partial and complete kits as well, so there’s something for everyone’s comfort level. Watch the POLY555 in action in the video, embedded below.

Continue reading “Peek Into This Synth’s Great Design (And Abandoned Features)” →

Open-Source Thermostat Won’t Anger Your Landlord

February 6, 2021 by Anool Mahidharia 51 Comments

[Nathan Petersen] built a Hackable Open-Source Thermostat to smooth out temperature fluctuations caused by the large hysteresis of the bimetallic strip thermostat in his apartment. While it may be tempting to adjust the “anticipator” to take care of the problem or even replace the bimetallic thermostat with an electronic version, building your own thermostat from scratch is a good way to add to your project portfolio while making your way through college. Plus, he got to hone his hardware and software design chops.

The hardware is designed around the STM32, using a cheap, minimal variant since the device just needs to sense temperature and control the furnace in on-off mode. The TMP117 high-accuracy, low-power, temperature sensor was selected for temperature measurement since accuracy was an essential feature of the project. Dry-contact output for the furnace is via a normally-open solid state relay (opto-isolator). For the user interface, instead of going the easy-route and using an I²C/SPI OLED or LCD display, [Nathan] used three 7-segment LED displays, each driven by an 8-channel constant current driver. The advantage is that the display can be viewed from across the room, and it’s brightness adjusted via PWM. Temperature set-point adjustment is via a simple slide potentiometer, whose analog voltage is read by the micro-controller ADC. To remind about battery replacement, a second ADC channel on the micro-controller monitors the battery voltage via a voltage divider. The PCB components are mostly surface mount, but the packages selected are easy enough to hand solder.

[Nathan]’s Github repo provides the hardware and firmware source files. The board is designed in Altium, but folks using KiCad can use either the awesome Altium2KiCad converter or the online service for conversion. (The results, with some minor errors that can be easily fixed, are quite usable.) Serendipitously, his PCB layout worked like a charm the first time around, without requiring any rework or bodge wires.

The firmware is a few hundred lines of custom bare-metal C code, consisting of drivers to interface with the hardware peripherals, a UI section to handle the user interface, and the control section with the algorithm for running the furnace. [Nathan] walks us through his code, digging into some control theory and filtering basics. After making a few code tweaks and running the thermostat for some time, [Nathan] concludes that it is able to achieve +0.1°F / -0.5°F temperature regulation with furnace cycles lasting about 10-15 minutes (i.e. 4-6 cycles per hour). Obviously, his well insulated apartment and a decent furnace are also major contributing factors. Moving on, for the next version, [Nathan] wants to add data collection capabilities by adding some memory and SD card storage, and use an RTC to allow seasonal adjustments or time-based set-points.

This is his first attempt at a “functional’ useful project, but he does love to build the occasional toy, such as this POV Top.

Feeling The KiCad 6 Electricity

February 4, 2021 by Kerry Scharfglass 72 Comments

In 2018, when KiCad Version 5 modernized the venerable 4.X series, it helped push KiCad to become the stable and productive member of the open source EDA landscape that we know today. It has supported users through board designs both simple and complex, and like a tool whose handle is worn into a perfect grip, it has become familiar and comfortable. For those KiCad users that don’t live on the bleeding edge with nightly builds it may not be obvious that the time of version 6 is nearly upon us, but as we start 2021 it rapidly approaches. Earlier this month [Peter Dalmaris] published a preview of the changes coming version 6 and we have to admit, this is shaping up to be a very substantial release.

Don’t be mistaken, this blog post may be a preview of new KiCad features but the post itself is extensive in its coverage. We haven’t spent time playing with this release yet so we can’t vouch for completeness, but with a printed length of nearly 100 pages it’s hard to imagine [Peter] left anything out! We skimmed through the post to extract a few choice morsels for reproduction here, but obviously take a look at the source if you’re as excited as we are. Continue reading “Feeling The KiCad 6 Electricity” →