Every body Had Tea ??? Cozy ?? Ok Lets start …

1. Every body Had Tea ??? • Cozy ?? • Ok Lets start …

2. NullCon Hardware Badge 101 Amey & Umesh

3. Who We are ? • Amey • Information Security Consultant • Earn wages through all regular stuff like VA, PT, WiFi Audits, Policy based audits, ISO-27001, yaada..yaadaa..yadaa • Moderator of www.garage4hackers.com • Electronics Enthusiastic • This year completed maze solving autonomous line follower robot using Atmega16. • R & D in hardware attack vectors in normal Network infrastructure • No Not USB based ! People have also written frameworks for it nothing new in it.

4. Who We are ? • Umesh • Pure Hardware/electronics Hacker • doesn't really like much involvement in normal web/network things • Repair and rebuild CNC Machines for living • the founder of Spartacus foundation which works for the Remand home/street children in Pune. • He does rock climbing and trekking in leisure time or sometimes full time for lots of days. • Some times drags innocent people like me in rock climbing :-D

5. What this talk is NOT about • Microcontroller Details • Microcontroller Programming details • Programmer Hardware circuit • If some one needs all this basic information, we have collected it and given the links/documents on NullCon.net website or will be posted on www.garage4hackers.com • We will only cover topics regarding creation of this badge

6. From G4H Both of us are also part of Hacker group G4h or www.Garage4Hackers.com About G4H: One of the top hackers group of India. Shouts: eby, punter, Anil & all other garage members… …b0nd screw you for not coming to NullCon

7. What ? • Hardware Badge • Programmable General Purpose Kit • Atmega8 • LED Output • Sound Output • Input switches • One Other Gadget • You people already guessed circuit ? Got Prize ?

8. The Other Circuit • Plan A • First thought was to provide only one gadget which was this EMF detector

9. The Other Circuit • You can check existance of A/C power supply without touching live wire or inserting any probe into power socket. • Just push the right most switch and take the circuit near any A/C wire. • If supply is going on you can see the LED glowing. • To recognize this circuit was Level 1 for Hardware badge competition. • Prize question: How this circuit’s range can be extended ?

10. Hardware Badge Competition • I think till now most of you have guessed what the other two things in competition • Second level was a string hidden in LED Persistence of Vision or POV • Third level was a string played via Morse code. • We even fitted a button which would play Morse code from AtoZ,0to9 with visual LED displaying Morse code of same character to help any one who wanted to understand Morse code quickly.

11. Why? • We have been seeing less Indian Hackers involved in Hardware Stuff ! • People don’t get much involved in Electronics / Embedded Systems, Microcontrollers. • So thought to encourage people by providing a general purpose kit for Microcontroller • One can program these circuits to learn about Microcontroller using any USB ASP AVR programmer available in market

12. Why? • We saw similar kind of kits are being sold in market from Rs.1500 to Rs. 3000.

13. Hardware hacking and India • I am actually jealous of Hardware people working US / UK etc… • I was amazed how simple it is to get componenets availabilty / price online and order components online directly throgh design softwares like Eagle. • Make circuit -> Check Component Availability -> Order … 1,2,3…Done

14. Hardware hacking and India • In India if you check before any circuit building you have to run across all market checking availability of electronics components. • The components ID are always given as per foreign manufacturers which have no resemblance here in electronics market. • Our students are always threatened against damage to electronic components • So not encouraged to experiment, though most easily damaged components are so cheap

15. Hardware hacking and India • Less use of Soft wares related to electronics • I found many persons having good electronics knowledge (such as one standing here with me) also didn’t knew what powers software could provide • Umesh was stunned when he saw I designed a PCB for a circuit by software such as Proteus, Eagle in just one day without any experience in PCB design • Lots of good software readily available

16. History • No We are not telling about Hardware or Microcontroller History • We are telling about this badge design history • Is it to long … ?? • Little Bit… :-D

17. Initial Idea • Why not a hardware badge instead of normal paper badges at NullCon • Thought produced at a Null+G4H+…. Meeting • My friend Anil who is seating here called me saying first thought after discussing electronics and hardware is to call me. • We had some initial discussions and ideas exchange.

18. R & D • There were lots of Ideas in consideration in the beginging • TV Remote Jammer • IR Communication • In R & D we had full working module with 16x2 Character LCD display, with Light and Temperature Sensors, Clock, stopwatch etc… • Some dropped due to $$$ • Some dropped due to less time in doing R & D • Some dropped due to Hardware components were too much in cost so again $$$

19. working module with 16x2 Character LCD display, with Light and Temperature Sensors, Clock, stopwatch

20. First look of EMF detector

21. First POV circuit

22. Switch Interface in R&D

23. R & D • At one stage even my wife was asking me are you ever gonna finalize what you will be making ? • Lots of research went in before finalizing the badge design. • Also faces problems in research such • as not getting proper components. • Local suppliers creating USB programmer circuits which defy international standards and brick our microcontrollers. • Badge size / circuit size • What functionalities to provide

24. R & D Credits • First important support for Our R & D… • My Wife Trupti … • Who encouraged us & provided us with unlimited supply of food / tea / coffee • And also kept my small angel daughter Ishani from taking our Soldering guns

25. Long journey... • It was a very long journey from the first prototype…

26. Long journey... • To actually getting first assembled pieces in hand…

27. Long journey... • After getting hands on First assembled piece also the journey was not over… • When testing first few samples we herd a sound… • Phhaaaatttt !!!! • What was it ??? • Show you on Next Slide…

28. Long journey... • Exploding LED • I am sure none of you have seen exploded LED. • Here have a look… • LED actually Broke into Half… • There was some problem while assembly due to which this happened…

29. Before First Assembled Piece • Sample on general Purpose PCB • Special PCB to be designed • Sample PCB to be made and checked • Getting 1 or 2 sample PCB from makers is getting milk from a bull. :-D I didn’t remember any other comparison while making slides sorry…  • Finalise Errors in the PCB • Finalise Ident (Front Printing on Badge)

30. Purchase Material • Too many people giving too many different rates • Every one saying others gives duplicate material • Getting information about verifying genuine components… Get quotations… • And at last…

31. Assembly • We are not regular customer • We get less priority than jobs in regular cycle • We cant push for credit or faster jobs easily • Don’t many choices on lower rates • Time Crunch… • We were late already due to PCB manufacturing • Assembly going on till last week before conference…

32. Lessons learned… • Being engineer doesn’t make person good at producing mass numbers of a product • Some engineer in your team would always want highest price things and you might be looking at budget. • Some engineer in your team thinks just show jazzy idea to sponsors and they will pour tons of money… It never happens… • Think of price before using any component. • Think of Availability on mass scale

33. Technical Lessons Learned • One should check various limits in local area manufacturers and suppliers before finalizing product circuit. • PCB Manufacturer • Components Suppler • Components Availability • Will the sling fit the PCB ??? ;-) • Actually this question rise when we were creating PCB

34. Technical Lessons Learned • Making changes in Circuit or changing whole circuit is better than fighting with suppliers and PCB manufacturers • When developing on mass scale (more than 100 pieces) add 1 month extra at least to timeline than what ever you think you will complete it in. :-D • Start development before hand according to time line in above statement

35. More lessons learned • Yes we have learned a lot in this one project… • Don’t involve all the engineers in other processes than R&D • Electronic engineer sometime thinks he knows it all but its not the case most of the times. • 220ohm is not replacement of 47ohm resistor • 5v buzzer is not correct for 3 volt supply • About PCB Manufacturers • About Component Suppliers

36. More lessons learned PCB Manufacturers • He is the person who will say you can draw tracks too narrow • He will say we cant drill small size drill than XYZ mm. • He would suddenly say his PCB designer is not available for next 10 days. • He would not even try what type of circuit design files are sent to him and say this is not our regular file type we want ABC type files.

37. More lessons learned PCB Manufacturers • This is guy who would say he cant create slot, so your sling might not fit in the PCB • People are not ready doing anything different from their regular routine. • Being hackers we had stretched them to a different level.

38. Components Suppliers • Prices • Availability of Components & Samples • Components matching to your PCB design • Components matching to you Circuit power supply. • I will leave aside biggest debate in market: Are these components Original or Duplicate. • Always Check components supplied are same in specs as we have ordered.

39. Hope you like it… • We hope you like the hardware badge • And do get involved in the AVR microcontrollers • So that next time we would see more people involved in Hardware / Embedded / Electronics. • Have nice time while Hardware Hacking !

40. Bye • Bye take care…