retrotechtacular

115 Articles

Retrotechtacular: Circuit Potting, And PCBs The Hard Way

June 15, 2023 by 8 Comments

There was a time when the very idea of building a complex circuit with the intention of destroying it would have been anathema to any electrical engineer. The work put into designing a circuit, procuring the components, and assembling it, generally with point-to-point wiring and an extravagant amount of manual labor, only to blow it up? Heresy!

But, such are the demands of national defense, and as weapons morphed into “weapon systems” after World War II, the need arose for electronics that were not only cheap enough to blow up but also tough enough to survive the often rough ride before the final bang. The short film below, simply titled “Potted and Printed Circuits“, details the state of the art in miniaturization and modularization of electronics, circa 1952. It was produced by the Telecommunications Research Establishment (TRE), the main electronics R&D entity in the UK during the war which was responsible for inventions such as radar, radio navigation, and jamming technology.

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Retrotechtacular: A Closer Look At The VT Proximity Fuze

June 9, 2023 by 16 Comments

Here at Hackaday, our aim is to bring you only the freshest of hacks, which carries the burden of being Johnny-on-the-spot with our source material. So if something of obvious interest to our readers goes viral, we might just choose to skip covering it ourselves, figuring you all have probably seen it already. But, if we can dig a little deeper and bring extra value over and above what the viral content provides — well then that’s another story.

That’s pretty much the story behind the excellent video recently released by [Real Engineering] about “The Secret Weapon That Changed World War 2.” It concerns the VT series of proximity fuzes — it’s a legitimate alternate spelling of “fuse” if a somewhat archaic one — that were used for artillery shells and spin-stabilized rockets in World War II. The video gives an excellent overview of the development of the VT, which was used primarily in anti-aircraft artillery (AAA). The details about the development of the American VT fuze are excellent, although curiously there’s no mention that British experiments with a radio proximity fuze were part of the goldmine of information brought to America at great risk by the Tizard mission in 1940. While there has been plenty of contention about the exact role the British work played, it’s fair to say that it at least informed the development and fielding of the American VT fuze.

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Retrotechtacular: Putting Pictures On The Wire In The 1930s

April 25, 2023 by 52 Comments

Remember fax machines? They used to be all the rage, and to be honest it was pretty cool to be able to send images back and forth over telephone lines. By the early 2000s, pretty much everyone had some kind of fax capability, whether thanks to a dedicated fax machine, a fax modem, or an all-in-one printer. But then along came the smartphone that allowed you to snap a picture of a document and send it by email or text, and along with the decrease in landline subscriptions, facsimile has pretty much become a technological dead end.

But long before fax machines became commonplace, there was a period during which sending images by wire was a very big deal indeed. So much so that General Motors produced “Spot News,” a short film to demonstrate how newspapers leveraged telephone technology to send photographs from the field. The film is very much of the “March of Progress” genre, and seems to be something that would have been included along with the newsreels and Looney Tunes between the double feature films. It shows a fictional newsroom in The Big City, where a cub reporter gets a hot tip about an airplane stunt about to be attempted out in the sticks. The editor doesn’t want to miss out on a scoop, so he sends a photographer and a reporter to the remote location to cover the stunt, along with a technology-packed photographic field car. Continue reading “Retrotechtacular: Putting Pictures On The Wire In The 1930s” →

Retrotechtacular: Gibson Factory Tour, 1967-Style

December 29, 2022 by 14 Comments

If nothing else good came out of 2020, we can say that we at least have “Instrument of the People” — some 1967-era footage of Gibson Guitars’ “craftory”, which was discovered sometime in the fall of 2020. It appears a bit boring at first — a suit slowly approaches the camera on a dimly-lit factory floor and you half-expect an ‘oh, I didn’t see you there’ type of introduction, but no. When he reaches the foreground, he finds a candy apple-red Gibson semi-hollow body guitar waiting for him. After giving the thing a quick once over, he assesses the straightness of the neck and then begins shredding on it, fingerpicking style.

If you like this or any type of guitar music, then hang on to your headstock, because it lilts nonstop throughout this 20-minute tour as we see a parade of nameless, and often headless, players showing their stuff on various styles of Gibson both electric and acoustic.

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Retrotechtacular: A 1960s Look At The 21st Century Home

December 15, 2022 by 29 Comments

If you only watch the first 60 seconds of 1967’s “At Home, 2001,” you’ll be forgiven for thinking that the film is riddled with missed predictions. And to be sure, the cold open is rife with them, from disposable paper furniture to seashell-shaped houses that look like they’re extruded from concrete. Really, the only clear winner from that first tranche of predictions is the rise of the microwave oven, which given the expense of magnetrons in 1967 and the complexity of the electronics needed to drive them was a non-obvious development.

But pushing beyond that opening to the meat of this film reveals a fair number of domestic trends that actually did manage to come true, at least partially, and if not by 2001 then shortly thereafter. The film is an educational piece hosted by iconic American newsman Walter Cronkite, who lends his gravitas to the proceedings. The film opens with “Uncle Walter” sonorously pontificating on the unsustainability of the “ticky tacky” spawl of the suburbs and how the situation simply must change.

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Retrotechtacular: 1990s CD Mastering Fit For A King

July 7, 2022 by 48 Comments

Before it was transformed into an ephemeral stream of ones and zeroes, music used to have a physical form of some kind. From wax cylinders to vinyl discs to tapes of various sizes in different housings and eventually to compact discs, each new medium was marketed as a technological leap over the previous formats, each of which justified incrementally more money to acquire.

But that’s the thing — each purchase resulted in you obtaining a physical item, which had an extensive manufacturing and distribution process behind it. And few artists demanded more manufacturing effort than Michael Jackson in his heyday, as revealed by this in-depth look at the CD manufacturing process for The King of Pop’s release of the HIStory double-disc set in 1995.

The video was produced as sort of a love letter to Michael from the staff and management of the Sony Music disc manufacturing plant in Pittman, New Jersey. The process is shown starting with the arrival of masters to the plant, strangely in the form of U-matic videocassettes; the 3/4″ continuous loop tape was normally used for analog video, but could also be used for recording digital audio. The digital audio is then sent for glass mastering, which is where the actual pits are created on a large glass disc under cleanroom conditions. In fact, much of the production process bears a strong similarity to semiconductor manufacturing, from the need for cleanrooms — although under less stringent conditions than in a fab — to the use of plasma etching, vapor deposition, and metal plating operations.

Once the master stampers are made, things really ramp up in replication. There the stamper discs go into injection molding machines, where hot polycarbonate is forced against the surface under pressure. The copies are aluminized, spin-coated with UV-cure lacquer, and sent on down the line to testing, screen printing, and packaging. Sony hired 40 extra full-time workers, who appear to have handled all the tedious manual tasks like assembling the jewel cases, to handle the extra load of this release.

As cheesy as this thank-you video may be, it was likely produced with good reason. This was a time when a Michael Jackson release was essentially a guarantee of full employment for a large team of workers. The team was able to produce something like 50,000 copies a day, and given that HIStory sold over 20 million copies, that’s a lot of workdays for the good folks at Pittman.

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Retrotechtacular: Clay Pipe The Hard Way

May 31, 2022 by 28 Comments

Troll YouTube long enough and chances are good that you’ll come across all kinds of videos of the “How It’s Made” genre. And buried in with the frying pans and treadmills and dental floss manufacturers, there no doubt will be deep dives on how pipe is made. Methods will vary by material, but copper, PVC, cast iron, or even concrete, what the pipe factories will all have in common is the high degree of automation they employ. With a commodity item like pipe, it’s hard to differentiate yourself from another manufacturer on features, so price is about the only way to compete. That means cutting costs to the bone, and that means getting rid of as many employees as possible.

Such was not always the case, of course, as this look at how Irish Stoneware & Fireclays Ltd. made clay pipe, drain tiles, and chimney flues back in the 1980s shows. The amount of handwork involved in making a single, simple piece of clay pipe is astonishing, as is the number of hands employed at the various tasks. The factory was located in Carrickmacross, County Monaghan, Ireland, near an outcropping of shale that forms the raw material for its products. Quarrying the shale and milling it into clay were among the few mechanized steps in the process; although the extrusion of the pipe itself was also mechanized, the machines required teams of workers to load and unload them.

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