At this point in the tech dystopia cycle, it’s no surprise that the initial purchase price of a piece of technology is likely not the last payment you’ll make. Almost everything these days needs an ongoing subscription to do whatever you paid for it to do in the first place. It’s ridiculous, especially when all you want to do is charge your electric motorcycle with electricity you already pay for; why in the world would you need a subscription for that?
That was [Maarten]’s question when he picked up a used EVBox wall mount charger, which refused to charge his bike without signing up for a subscription. True, the subscription gave access to all kinds of gee-whiz features, none of which were necessary for the job of topping off the bike’s battery. A teardown revealed a well-built device with separate modules for mains supply and battery charging, plus a communications module with a cellular modem, obviously the bit that’s phoning home and keeping the charger from working without the subscription.
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.
While hardly necessary for this design, you can also import graphics into a KiCad schematic in a similar manner to the PCB editor. First, convert the CorelDRAW file into DXF or SVG — I used InkScape to make an SVG. Next do Import -> Graphics in the Kicad schematic editor. However, you immediately realize that, unlike the PCB editor, the schematic editor doesn’t have any concept of drawing layers. As a work around, you can instead import graphics into a new symbol, and place this symbol on a blank page. I’m not sure how helpful this would be in tracing out schematics in a real world scenario, since I just drew mine from scratch. But it’s worth trying if you have complex schematics.
Note: this didn’t work perfectly, however. For some reason, the text doesn’t survive being imported into KiCad. I attribute this to my poor InkScape skills rather than a shortcoming in KiCad or CorelDRAW. Despite having no text, I put this symbol on its own page in sheet two of the schematic, just for reference to see how it can be done.
Just like last year, the footprints in the Circuit Maker PCB file were imported into KiCad in a seemingly random manner. Some footprints import as expected. Others are imported such that each individual pad is a standalone footprint. This didn’t cause me any problems, since I made all new footprints by modifying standard KiCad ones. But if you wanted to save such a footprint-per-pad part into a single KiCad footprint, it would take a bit more effort to get right.
Recreating Schematics and Parts
After redrawing the schematics, I focused on getting the part footprints sorted out. I did them methodically one by one. The process went as follows for each part:
Start with the equivalent footprint from a KiCad library
Duplicate it into a local project library
Add the text SAO to the footprint name to avoid confusion.
Position and align the part on the PCB atop the imported footprint
Note and adjust for any differences — pad size and/or shape, etc.
Update the part in the project library
Attach it to the schematic symbols in the usual manner.
Delete the imported original footprint (can be tricky to select)
Some parts were more interesting than others. For example, the six SAO connectors are placed at various non-obvious angles around the perimeter. I see that [Voja] slipped up once — the angle between connectors 4 and 5 is at a definitely non-oddball angle of 60 degrees.
With all this complete, the PCB artwork consists of all new footprints but uses the original traces. I needed to tweak a few traces here and there, but hopefully without detracting too much from [Voja]’s style. Speaking of style, for those interested in giving that free-hand look to hand-routed tracks in KiCad, check the options in the Interactive Router Settings menu. Choose the Highlight collisions / Free angle mode and set the PCB grid to a very small value. Free sketch away.
Glitches
Actual jumper on assembled PCB
Circuit Maker PCB File
Schematics showing jumper
I used two photos of the actual board to check when something wasn’t clear. One such puzzle was the 3-pad SMT solder ball jumper. This was shown on the schematic and on the fully assembled PCB, but it was not in the Circuit Maker design files. I assumed that the schematics and photos were the truth, and the PCB artwork was a previous revision. There is a chance that I got it backwards, but it’s an easy to fix if so. Adding the missing jumper took a bit of guesswork regarding the new and adjusted traces, because they were hard to see and/or underneath parts in the photo. This redrawn design may differ slightly in appearance but not in functionality.
DRC checks took a little more iterating than usual, and at one point I did something to break the edge cuts layer. The irregular features on this PCB didn’t help matters, but I eventually got everything cleaned up.
I had some trouble sometimes assigning nets to the traces. If I was lucky, putting the KiCad footprint on top of the traces assigned them their net names. Other times, I had traces which I had to manually assign to a net. This operation seemed to work sporatically, and I couldn’t figure out why. I was missing a mode that I remember from another decade in a PCB tool, maybe PCAD?, where you would first click on a net. Then you just clicked on any number of other items to stitch them into the net. In KiCad it is not that simple, but understandable given the less-frequent need for this functionality.
You may notice the thru hole leads on the 3D render are way too long. Manufacturers provide 3D files describing the part as they are shipped, which reasonably includes the long leads. They are only trimmed at installation. The virtual technician inside KiCad’s 3D viewer works at inhuman speeds, but has had limited training. She can install or remove all through hold or SMT parts on the board, in the blink of an eye. She can reposition eight lamps and change the background color in mere seconds. These are tasks that would occupy a human technician for hours. But she doesn’t know how to trim the leads off of thru hole parts. Maybe that will come in future versions.
Project Libraries
I like to extract all symbols, part footprints, and 3D files into separate project libraries when the design wraps up. KiCad experts will point out that for several versions now this is not necessary. All (or most) of this information is now stored in the design files, alghouth with one exception — the 3D files. Even so, I still feel safer making these project libraries, probably because I understand the process.
KiCad can now do this with a built-in function. See the Export -> Symbols to New Library and Export -> Footprints to New Library in the schematic and PCB editors, respectively. These actions give you the option to additionally change all references in the design to use this new library. This didn’t work completely for me, for reasons unclear. Eventually I just manually edited the sch and pcb file and fixed the library names with a search and replace operation.
Hint: When configuring project libraries in KiCad, I always give them a nickname that begins with a dot. For example, .badge24 or .stumbler. This always puts project libraries at the top of the long list of libraries, and it makes it easier to do manual search and replaces in the design files if needed.
What about 3D files, you say? That isn’t built into KiCad, but have no fear. [Mitja Nemec] has you covered with the Archive 3D Models KiCad plugin. It was trivial to activate and use in KiCad’s Plugin and Content Manager.
All Done
In the end, the design passed all DRCs, and I could run Update PCB from Schematic... without errors. I went out on a limb and immediately placed an order for five PCBs, hoping I hadn’t overlooked something. But it’s only US$9.00 risk. They are on the way from China as I type this.
All the files can be found in this GitHub repo. If you find any errors, raise an issue there. I have not done this procedure for any of the SAO petals, but when I do, I will place a link in the repository.
All your Nintendo Alarmo are belong to mew~ (Credit: GaryOderNichts, Blogspot)
Most of us will probably have seen Nintendo’s latest gadget pop up recently. Rather than a Switch 2 announcement, we got greeted with a Nintendo-branded alarm clock. Featuring a 2.8″ color LCD and a range of sensors, it can detect and respond to a user, and even work as an alarm clock for the low, low price of €99. All of which takes the form of Nintendo-themed characters alongside some mini-games. Naturally this has led people like [Gary] to buy one to see just how hackable these alarm clocks are.
As can be expected from a ‘smart’ alarm clock it has 2.4 GHz WiFi connectivity for firmware and content download, as well as a 24 GHz millimeter wave presence sensor. Before [Gary] even had received his Alarmo, others had already torn into their unit, uncovering the main MCU (STM32H730ZBI6) alongside a 4 GB eMMC IC, as well as the MCU’s SWD pads on the PCB. This gave [Gary] a quick start with reverse-engineering, though of course the MCU was protected (readout protection, or RDP) against firmware dumps, but the main firmware could be dumped from the eMMC without issues.
After this [Gary] had a heap of fun decrypting the firmware, which seems to always get loaded into the external octal SPI RAM before execution, as per the boot sequence (see featured image). This boot sequence offers a few possibilities for inserting one’s own (properly signed) contents. As it turns out via the USB route arbitrary firmware binaries can be loaded, which provided a backdoor to defeat RDP. Unfortunately the MCU is further locked down with Secure Access Mode, which prevents dumping the firmware again.
So far firmware updates for the Alarmo have not nailed shut the USB backdoor, making further reverse-engineering quite easy for the time being. If you too wish to hack your Alarmo and maybe add some feline charm, you can check [Gary]’s GitHub project.
Over the decades the technology behind flat panel displays has continuously evolved, and we’ve seen many of them come and go. Among the popular ones there are a few that never quite made the big time, usually because a contemporary competitor took their market. An example is in a recent [Wenting Zhang] video, a mystery liquid powder display. We’d never heard of it, so we were intrigued.
The first segment of the video is an examination of the device, and a comparison with similar-looking ones such as a conventional LCD, or a Sharp Memory LCD. It’s clearly neither of those, and the answer finally came after a lot of research. A paper described a “Quick response liquid powder” as a mechanism for a novel display, and thus it was identified. It works by moving black and white electrically charged powder to flip a pixel from black to white, and its operation is not dissimilar to the liquid-based e-ink displays which evidently won that particular commercial battle.
The process of identifying the driver chip and pinout should be an essential watch for anyone with an interest in display reverse engineering. After a lot of adjusting timing and threshold voltages the dead pixels and weird effects fall away, and then it’s possible to display a not-too-high-quality image on this unusual display, through a custom PCB with an RP2040. Take a look at the video below the break.
As far as impressive hacks go, this one is more than enough for your daily quota. You might remember the ROG Ally, a Steam Deck-like x86 gaming console that’s graced our pages a couple lf times. Now, this is a big one – from the ROG Ally community, we get a fully open-source eGPU adapter for the ROG Ally, built by reverse-engineering the proprietary and overpriced eGPU sold by Asus.
We’ve seen this journey unfold over a year’s time, and the result is glorious – two different PCBs, one of them an upgraded drop-in replacement board for the original eGPU, and another designed to fit a common eGPU form-factor adapter. The connector on the ROG Ally is semi-proprietary, but its cable could be obtained as a repair part. From there, it was a matter of scrupulous pinout reverse-engineering,logic analyzer protocol captures, ACPI and BIOS decompiling, multiple PCB revisions and months of work – what we got is a masterpiece of community effort.
Do you want to learn how the reverse-engineering process has unfolded? Check out the Diary.md – it’s certainly got something for you to learn, especially if you plan to walk a similar path; then, make sure to read up all the other resources on the GitHub, too! This achievement follows a trend from the ROG Ally community, with us having featured dual-screen mods and battery replacements before – if it continues the same way, who knows, maybe next time we will see a BGA replacement or laser fault injection.
It can often feel like modern devices are less hackable than their thicker and far less integrated predecessors, but perhaps it’s just that our techniques need to catch up. Here’s an outstanding hack that adds a dual SIM slot to a US-sold eSIM iPhone 15/15 Pro, while preserving its exclusive mmwave module. No doubt, making use of the boardview files and schematics, it shows us that smartphone modding isn’t dead — it could be that we need to acknowledge the new tools we now have at our disposal.
When different hardware features are region-locked, sometimes you want to get the best of both worlds. This mod lets you go the entire length seamlessly, no bodges. It uses a lovely looking flexible printed circuit (FPC) patch board to tap into a debug header with SIM slot signals, and provides a customized Li-ion pouch cell with a cutout for the SIM slot. There’s just the small matter of using a CNC mill to make a cutout in the case where the SIM slot will go, and you’ll need to cut a buried trace to disable the eSIM module. Hey, we mentioned our skills needed to catch up, right? From there, it appears that iOS recognizes the new two SIM slots seamlessly.
The video is impressive and absolutely worth a watch if modding is your passion, and if you have a suitable CNC and a soldering iron, you can likely install this mod for yourself. Of course, you lose some things, like waterproofing, the eSIM feature, and your warranty. However, nothing could detract from this being a fully functional modkit for a modern-day phone, an inspiration for us all. Now, perhaps one of us can take a look at building a mod helping us do parts transplants between phones, parts pairing be damned.
It’s a well-known secret that inkjet ink is being kept at artificially high prices, which is why many opt to forego ‘genuine’ manufacturer cartridges and get third-party ones instead. Many of these third-party ones are so-called re-manufactured ones, where a third-party refills an empty OEM cartridge. This is increasingly being done due to digital rights management (DRM) reasons, with tracking chips added to each cartridge. These chip prohibit e.g. the manual refilling of empty cartridges with a syringe, but with the right tweak or attack can be bypassed, with [Jay Summet] showing off an interesting HP cartridge DRM bypass using a physical man-in-the-middle-attack.
This bypass takes the form of a flex PCB with contacts on both sides which align with those on the cartridge and those of the printer. What looks like a single IC in a QFN package is located on the cartridge side, with space for it created inside an apparently milled indentation in the cartridge’s plastic. This allows is to fit flush between the cartridge and HP inkjet printer, intercepting traffic and presumably telling the printer some sweet lies so that you can go on with that print job rather than dash out to the store to get some more overpriced Genuine HP-approved cartridges.
Not that HP isn’t aware or not ticked off about this, mind. Recently they threatened to brick HP printers that use third-party cartridges if detected, amidst vague handwaving about ‘hackers’ and ‘viruses’ and ‘protecting the users’ with their Dynamic Security DRM system. As the many lawsuits regarding this DRM system trickle their way through the legal system, it might be worth it to keep a monochrome laser printer standing by just in case the (HP) inkjet throws another vague error when all you want is to just print a text document.
