Supercon 2024 SAO Petal KiCad Redrawing Project

November 19, 2024 by Chris Lott 4 Comments

Last week I completed the SAO flower badge redrawing task, making a complete KiCad project. Most of the SAO petals are already released as KiCad projects, except for the Petal Matrix. The design features 56 LEDs arranged in eight spiral arms radiating from the center. What it does not feature are straight lines, right angles, nor parts placed on a regular grid.

Importing into KiCad

Circuit Notes for LEDs, Thanks to [spereinabox]

I followed the same procedures as the main flower badge with no major hiccups. This design didn’t have any released schematics, but backing out the circuits was straightforward. It also helped that user [sphereinabox] over on the Hackaday Discord server had rung out the LED matrix connections and gave me his notes.

Grep Those Positons

I first wanted to only read the data from the LEDs for analysis, and I didn’t need the full Kicad + Python scripting for that. Using grep on the PCB file, you get a text file that can be easily parsed to get the numbers. I confirmed that the LED placements were truly as irregular as they looked.

My biggest worry was how obtain and re-apply the positions and angles of the LEDs, given the irregular layout of the spiral arms. Just like the random angles of six SAO connector on the badge board, [Voja] doesn’t disappoint on this board, either. I fired up Python and used Matplotlib to get a visual perspective of the randomness of the placements, as one does. Due to the overall shape of the arms, there is a general trend to the numbers. But no obvious equation is discernable.

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Supercon 2024 Flower SAO Badge Redrawing In KiCad

October 31, 2024 by Chris Lott 12 Comments

Out of curiosity, I redrew the Supercon Vectorscope badge schematics in KiCad last year. As you might suspect, going from PCB to schematic is opposite to the normal design flow of KiCad and most other PCB design tools. As a result, the schematics and PCB of the Vectorscope project were not really linked. I decided to try it again this year, but with the added goal of making a complete KiCad project. As usual, [Voja] provided a well drawn schematic diagram in PDF and CorelDRAW formats, and a PCB design using Altium’s Circuit Maker format (CSPcbDoc file). And for reference, this year I’m using KiCad v8 versus v7 last year.

Importing into KiCad

This went smoothly. KiCad imports Altium files, as I discovered last year. Converting the graphic lines to traces was easier than before, since the graphical lines are deleted in the conversion process. There was a file organizational quirk, however. I made a new, empty project and imported the Circuit Maker PCB file. It wasn’t obvious at first, but the importing action didn’t make use the new project I had just made. Instead, it created a completely new project in the directory holding the imported Circuit Maker file. This caused a lot of head scratching when I was editing the symbol and footprint library table files, and couldn’t figure out why my edits weren’t being seen by KiCad. I’m not sure what the logic of this is, was an easy fix once you know what’s going on. I simply copied everything from the imported project and pasted it in my new, empty project. Continue reading “Supercon 2024 Flower SAO Badge Redrawing In KiCad” →

Hacker Tactic: Building Blocks

October 24, 2024 by Arya Voronova 11 Comments

The software and hardware worlds have overlaps, and it’s worth looking over the fence to see if there’s anything you missed. You might’ve already noticed that we hackers use PCB modules and devboards in the same way that programmers might use libraries and frameworks. You’ll find way more parallels if you think about it.

Building blocks are about belonging to a community, being able to draw from it. Sometimes it’s a community of one, but you might just find that building blocks help you reach other people easily, touching upon common elements between projects that both you and some other hacker might be planning out. With every building block, you make your or someone else’s next project quicker, and maybe you make it possible.

Sometimes, however, building blocks are about being lazy.

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Hacker Tactic: Multi-Design Panels

July 29, 2024 by Arya Voronova 12 Comments

Last time, we talked about single-PCB-design panels, all the cool aspects of it, including some cost savings and handling convenience. Naturally, you might wonder, and many did – can you put multiple different PCBs on a single panel? The answer is “yes, without a doubt!” The tool we used last time, KiKit, will not be as helpful here, so we’ll be looking elsewhere.

Making multi-PCB panels can help you save money, naturally, but it can also make your assembly a whole lot easier, and it can bring you hacking to a whole new level. It sure helped with mine! You might have already learned that some fabs scoff at multi-design panels and add surcharges. Well, you’ll be delighted to learn that there are more hacker-friendly fabs out there, too.

Developing PCBs In Bulk

So far, I’ve worked on about 300 different PCB designs, with half of them available in my monorepo. I’ve assembled and tested just about half of these. You might guess that this would cost a lot of money, and that assembly would take a fair bit of time, but I have some tricks up my sleeve. For a start, you can easily order PCBs 10-12 times more cheaply if you do multi-panel.

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PCB Design Review: HAB Tracker With ATMega328P

July 10, 2024 by Arya Voronova 15 Comments

Welcome to the Design Review Central! [VE3SVF] sends us their board, and it’s a HAB (High Altitude Balloon) tracker board. It’s got the venerable ATMega28P on it, a LoRa modem and a GPS module, and it can be powered from a LiIon battery. Stick this board with its battery onto a high-altitude balloon, have it wake up and transmit your coordinates every once in a while, and eventually you’ll find it in a field – if you’re lucky. Oherwise, it will get stuck hanging on a tree branch, and you will have to use a quadcopter to try and get it down, and then, in all likelihood, a second quadcopter so that you can free the first one. Or go get a long ladder.

The ATMega328P is tried and true, and while it’s been rising in price, it’s still available – with even an updated version that sports a few more peripherals; most importantly, you’re sure to find a 328P in your drawer, if not multiple. Apart from that, the board uses two modules from a Chinese manufacturer, G-Nice, for both GPS and Lora. Both of these modules are cheap, making this tracker all that more accessible; I could easily see this project being sold as a “build your own beacon” kit!

Let’s make it maybe a little nicer, maybe a little cheaper, and maybe decrease the power consumption a tad along the way. We’ll use some of the old tricks, a few new ones, and talk about project-specific aspects that might be easy to miss.

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Too Much Over-optimization Is Never Enough!

March 30, 2024 by Elliot Williams 21 Comments

A discussion came up on the Hackaday Discord PCB design channel about resistor networks, and it got me thinking about whether we (the hacker community) use them in designs or not. These handy devices often take the shape of an IC, SMD or otherwise, but between the pins are a bunch of resistors instead of active silicon. They come in all sorts of configurations and tolerances, but the point is usually the same: When you need a bunch of similar resistors, it’s cheaper to go with a network package.

But how much cheaper? I did a quick search for 1 kΩ resistors and the corresponding network, and came up with similar prices for the resistors and networks – but the network has eight resistors in it! That’s an eightfold savings! Which, at a price of roughly one cent per piece, is less than a dime. While it’s certainly true that if you’re making a million widgets, saving a penny per widget matters. But do you spend the time to optimize your projects down to such margins? I want to say “of course not!” but maybe you do?

For me, worrying about seven cents in a PCB design that I may make ten of is foolishness. But still, I’ve used resistor networks for their other side effects: the resistors in a common package tend to be very tightly matched, even if their overall tolerance isn’t. If you’re making something like an R-2R DAC, that’s a definite advantage. Or if you’re space constrained, or just hate placing lots of tiny resistors, the networks shine.

I often forget about resistor networks, and when I do think of them, I think of them in terms of cost savings in industrial applications. But maybe that’s not fair – maybe they do have their hacker uses as well. Are there other parts like this that we should all know about?

Check Your Board: Call For Submissions

December 8, 2023 by Arya Voronova 41 Comments

As both beginning hackers and Silicon Valley investors alike keep discovering, there are a lot of differences between hardware and software. One important difference is cost of iterating over a design. In software, you can comfortably rerun your build process and push updates out near instantly to tons of users. In hardware, all of that costs money, and I do mean, it costs way more money than you’d want to spend.

When I see people order boards that could never work because of some fundamental design assertions, with mistakes entirely preventable, it hurts. Not in an “embarrassment” way – it’s knowing that, if they asked someone to take a look at the design, they could’ve received crucial feedback, pulled the traces on the board differently or added some components, and avoided spending a significant chunk of money and time expecting and assembling a board that has a fundamental mishap.

Every thing like this might set a beginner back on their hacker journeys, or just have them spend some of their valuable time, and we can do a ton to prevent that by simply having someone experienced take a look.

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