HackerBox 0068: SAO Showcase

Hello HackerBox Hackers!

Are you ready for the summer?
Are you ready for the badgelife?
Are you ready for the Villages,
The CTFs,
And a whole lot of hackin' around?

HackerBox 0068 is a showcase of electronic badge add-ons. We will assemble fifteen fabulous SAO kits, an SAO Power Badge, and a pair of six-port SAO Showcase boards. Working with a variety of LED technologies, we will hone our soldering skills and take on the SMD soldering challenge. We'll explore artistic printed circuit board design techniques. We'll also program the exclusive Wi-Fi SAO using the Arduino IDE to implement an embedded web server and other network-enabled features. It's time to live the #badgelife.

Check out our Official Video for HackerBox 0068.

HackerBoxes is the monthly subscription box for enthusiasts of electronics and computer technology - Hardware Hackers - The Dreamers of Dreams.

There is a wealth of information for current and prospective members in the HackerBoxes FAQ. Almost all of the non-technical support emails that we receive are already answered there, so we'd really appreciate it if you can take a few minutes to read the FAQ.

Supplies

This Instructable contains information for getting started with HackerBox 0068. The full box contents are listed on the product page for HackerBox 0068 where the box is also available for purchase while supplies last. If you would like to automatically receive a HackerBox like this right in your mailbox each month with a $15 discount, you can subscribe at HackerBoxes.com and join the revolution!

A soldering iron, solder, and basic soldering tools are generally needed to work on the monthly HackerBox. A computer for running software tools is also required. Have a look at the HackerBox Deluxe Starter Workshop for a set of basic tools and a wide array of introductory activities and experiments.

Most importantly, you will need a sense of adventure, hacker spirit, patience, and curiosity. Building and experimenting with electronics, while very rewarding, can be tricky, challenging, and even frustrating at times. The goal is progress, not perfection. When you persist and enjoy the adventure, a great deal of satisfaction can be derived from this hobby. Take each step slowly, mind the details, and don't be afraid to ask for help.

Step 1: LEDs - Nine Different Ones

There a lot of small components for HackerBox 0068. Let's go through and make sure we can tell them all apart and also learn how to correctly position each one for soldering.

There are nine different types of LEDs for your blinkly pleasure. LEDs are polarized and must be oriented correctly in order to work. There are a variety of marking techniques to indicate which of the LED terminals is the anode (+) and which is the cathode (-). Refer to this image while assembling the SAO projects to verify proper LED orientation.

Step 2: Not LEDs - the Other Components

We also have a number of "non-LED" components. Most important, are the 2X3 pin headers. As we will see, these are specified by the SAO Standard for connection between SAOs and badges.

Female SAO Headers

The thirteen keyed 2x3 Female headers are used on the badge side of the connection. One will be used on the SAO Power Badge and six go on each one of the SAO Showcase board. Always be sure to orient the keying block in the upward direction.

Male SAO Headers

The Add-On side of the connection is a 2x3 Male header. Eight of the SAOs feature 2x3 through-hole headers and use the shrouded 2x3 male connectors. The remaining seven SAOs feature 2x3 surface-mount headers formed by snapping off a section of the 2x40 male SMD header.

The 1x40 right angle header can be snapped apart for use at the lower edge of the two SAO Showcase boards.

Step 3: SAO Badgelife

OK - So what the heck is an SAO?

The Hackaday article entitled INTRODUCING THE SH*TTY ADD-ON V1.69BIS STANDARD by Brian Benchoff tells us that the SAO standard defines how we put smaller PCBs onto bigger PCBs. Basically, SAOs are little badges that we can add-on to our conference badges. The SAO standard employs a simple 2x3 pin header connection and "is supported by tens of thousands of badges, and all of the people who are spending their free time designing electronic conference badges are using this standard."

Click into Brian's excellent article for the history of SAOs and to learn the technical specification for the six-pin SAO V.1.69bis standard.

You can also check out the video Design an SAO in KiCAD with Alex Glow and review the Hackaday articleSimple Add-ons (SAO) by Twinkle Twinkie.

Step 4: SAO Power Badge Kit

But wait - What if I don't have a badge with an SAO port?

The SAO Power Badge is a little badge with only one function. It powers an SAO. It's a great way to display one SAO in all of its glory.

Assembly:

1. The power switch is small so solder that first
2. Tin all three pads for the coin cell clip with a thin layer of solder
3. Orient the coin cell clip according to the PCB silkscreen and solder the tabs to the PCB
4. Place one FEMALE 2x3 header on the front of the PCB (opposite side from the coin cell)
5. Make sure the keying block on the 2x3 header faces up (towards the smiling emoji)
6. Solder the 2x3 header into place

Step 5: SAO Showcase Kit

But wait again - What if I have a collection of SAOs and I want to display several of them at once?

Each of the two SAO Showcase boards can display and power six SAOs at once.

Assembly:

Six Female 2x3 Headers: Solder these on the opposite side of the PCB from the HackerBoxes logo. The logo text is the back of the PCB and the SAO headers go on the front of the PCB. Again, we sure to orient the keying block on the 2x3 Header towards the upper edge of the board.

Single Row Header: The row of holes along the bottom of each SAO Showcase board allows connection of power (3.3V only), ground, I2C (SDA and SCL), and GPIO pins. In reality, most SAOs use only 3V3 and GND pins, but the other four pins are there for SAOs that use them.

The 1x40 right angle header can be snapped apart and soldered for these connections. We suggest putting the header pins on the back side of the SAO Showcase board (the side with the HackerBoxes logo) to keep things tidy. Which direction you orient the pins (towards the edge of the PCB or away from the edge) is your option and might depend upon how you plan to mount the boards.

Once assembled, power can be supplied by connecting the 3V3 and GND pins from the CH340E Serial USB Module.

Step 6: HackerBox Bit Head SAO Kit

The Bit Head SAO is a miniaturized version of the HackerBox BadgeBuddy.

It is a simple and fun kit for introducing soldering skills. It features two self-cycling RGB LEDs to provide a cool, colorful effect.

The BadgeBuddy is featured in the HackerBoxes Learn to Solder Workshop, which was originally streamed from the Hardware Hacking Village during DEF CON 28. You might want to watch that video now.

HackerBox Bit Head SAO Kit Assembly:

1. The two LEDs go on the front (skull face) side of the PCB
2. Note the markings on the PCB for which direction to orient the LEDs
3. The Shrouded Male SAO header goes on the back side of the PCB
4. Be sure to orient the SAO header with the keying notch up

Step 7: Hologram Summer Camp SAO Kit

This is the world's first ever holographic SAO (as far as we know).

Hacker Summer Camp refers to three events held in Las Vegas each summer:

• DEF CON August 5 - 8, 2021
• Black Hat July 31 - August 5, 2021
• BSides Las Vegas (virtual for 2021)

When attending summer camp, be sure to visit HackerBoxes in the DEF CON Vendor Room. We'd love see you! If you've never attended, check out the DEF CON Documentary to see what you've been missing.

Hologram Summer Camp SAO Kit Assembly:

1. Place the holographic overlay onto the front of the PCB
2. Push a wire through the LED holes from the back marking their position on the overlay
3. Using a razor, cut and remove the overlay away from the metal pads for the LED
4. Insert the LED into the front of the PCB
5. Check the correct orientation of the LED and solder it into place
6. Snap off a 2x3 section of the 2x40 male SMD header
7. Solder the 2x3 header to the pads on the rear of the SAO

When using the 2x3 SMD headers, be sure to use plenty of solder at each pin and to achieve excellent solder flow between the pad and the pin. This is important because the SAO header solder joints must mechanically support the SAO.

Step 8: Fat Pika SAO Kit

This updated Fat Pika SAO design was contributed by renown badgelife designer Twinkle Twinkie. He made his original version of Fat Pika for DEF CON 26. Note that the original had the older four-pin style SAO connector. The updated Fat Pika is reduced in size (to comply with the standard) and uses the more secure six-pin V.1.69bis SAO standard.

You can follow Twinkle Twinkie at @mrtwinkletwink
Meet him in this Hak5 interview
View more of his projects on Hackaday, and
Support his work on tindie (you know you want to pick up "The Child" ASAP)

Fat Pika SAO Kit Assembly:

1. Solder the 43 Ohm (0805 package) resistor into place
2. Reverse-mount the two LHT774 LEDs with the corner notch closest to the cathode (-) pad
3. Solder the shrouded male SAO header with the keying notch up

If you're new to surface mount soldering, you might want to watch our SMT demo video or even get some extra practice with a HackerBox Soldering Workshop.

We asked Twinkle Twinkie, and our other contributing designers, a few questions to pick their brains. It is very interesting to hear what these amazing designers think about the creative process and what thoughts they are having about future projects...

What do you find most interesting or challenging about combining artistic expression into electronic designs?
For me the most interesting and challenging aspects are the same thing and that's the limitations brought on by using a non-artistic medium in an artistic way. I love exploring the limitations of manufacturing processes to create unconventional art in an unconventional way.

Thinking of a badge or SAO design that you really admire, what about it speaks to you?
My favorite designs are ones that do something unexpected or stretch the medium in ways it was never meant to, for instance using a copper finish that is rarely seen or doing things that are generally discouraged like applying the silk screen directly to the substrate, when it is typically applied on top of the solder mask.

If you had to design something today purely for fun, what would it be?
I design most everything I've done for fun. If I didn't think it was fun I wouldn't be doing it. My favorite "for fun" projects have been "Peanut Butter Jar" which says "GIF" emulating the "JIF" peanut butter brand and "Wireshark" which was a collaboration with Nick Pisarro which looks like a shark in a wire spool and plays a midi version of the "Baby Shark" children's song.

Step 9: Laughing Skull SAO Kit

The Laughing Skull SAO is a tribute to the Vortex Bar and Grill and Laughing Skull Beer. The original Laughing Skull SAO was designed by Twinkle Twinkie with a minor mod by hwboxer to incorporate the more secure six-pin V.1.69bis SAO standard. Both Twinkle Twinkie and hwboxer have strong connections to the ATL, home of the Vortex Bar and Grill (featured here on Man v. Food).

Laughing Skull SAO Kit Assembly:

1. Solder the 43 Ohm (0805 package) resistor into place
2. Reverse-mount the nine LHT774 LEDs with the corner notch closest to the cathode (-) pad
3. Solder the shrouded male SAO header with the keying notch up

Step 10: Kuchi Kopi SAO Kit

The Kuchi Kopi SAO was contributed by thehebrew. You can follow him @HebrewzHammer and support his work on tindie.

Kuchi Kopi's LEDs are side view and glow white (even though the look yellowish when they are off). The LEDs are mounted sideways as shown in the closeup. The green line on each LED must be oriented closest to the cathode (-) side of its respective PCB pads. Note that the center landing pad at each LED is not connected to anything and does not need to be soldered.

Melting clear hot glue on the back of the PCB, over both LEDs of an eye, and completely onto the eye area can act as a light pipe to help guide the light into and through the PCB. This can provide an improved glowing effect on the front side as presented in Using Side View LEDs on Hackaday by Twinkle Twinkie. The light still shows up pretty well even without the hot glue hack so it is totally optional, but it is worth experimenting with.

Kuchi Kopi SAO Kit Assembly:

1. Solder two 10 Ohm (0805 package) resistors into place
2. Solder four side view (1206 package) LEDs into place (mind the polarity)
3. Solder on the shrouded male SAO header with the keying notch up

We also asked thehebrew our three questions to consider...

What do you find most interesting or challenging about combining artistic expression into electronic designs?
I love being able to take art or something you love and that makes you laugh or happy, and then make it a physical real-world object infused with electronics! The real challenge to me is trying to do fun and interesting things with the electronics that enhance the art, while trying to keep the design simple and clean.

Thinking of a badge or SAO design that you really admire, what about it speaks to you?
There’s so many to choose from! But a personal favorite is Bliss Jourdan’s DEF CON 27 MULTI PASS Badge. Besides it being based on something from my favorite movie (The Fifth Element), the badge’s design was such a perfect blend of form and function! From the way all the inputs were integrated into the art via capacitive touch buttons, the perfect placement and amount of LEDs, to the integration of the e-ink screen that maintains the last thing displayed on it even when powered off.

If you had to design something today purely for fun, what would it be?
Well, I’ve already finished up my next SAO and just need to stop procrastinating so I can get it out there already (firmware scope creep!). So, keep an eye out for the Golden Turd SAO. But my next project is something I’ve been thinking about for a while and will be a full-fledged badge based on one of my favorite comics: Judge Dredd. It’s going to be much more complicated than my previous projects, but I really want it to be something people can interact with and also use to be able to interact with other people!

Step 11: No Cloud SAO Kit

The No Cloud SAO was designed by Jonathan Singer: security guru, DEF CON Goon, and host of the infamous Florida_Man Party. You can follow him on twitter @jonathansinger, see more of his projects on Hackaday, and support his future projects here.

Assembly of the No Cloud SAO Kit exactly parallels the Kuchi Kopi SAO Kit. The notes about LED orientation and hot glue experimentation apply equally here.

We also hit Jonathan up with our three questions...

What do you find most interesting or challenging about combining artistic expression into electronic designs?

Creativity doesn’t come easy to me so I often seek help from friends like @infosecanon for graphics and art. I will get a crazy idea and start working on the circuit schematics, but translating my thoughts into something aesthetically pleasing is a community effort.

Thinking of a badge or SAO design that you really admire, what about it speaks to you?

I love badges of function and purpose well after the conference they are found at are over. When you can repurpose the hardware, or the badge as a tool that you can add to your arsenal of hacking equipment, it keeps it from collecting dust and adds to the mystique.

If you had to design something today purely for fun, what would it be?

I have a few ideas that I’m bouncing around for future projects, but anything gaming related is always a win with me. I’m a huge fan of classics played on emulators, so within that genre would be a big hit with me and I hope anyone who got their hands on the design.

Step 12: Peanut Butter SAO Kit

The Peanut Butter SAO was designed by Twinkle Twinkie. All of the other SAOs featured here get by with only two metal layers within the PCB. The Peanut Butter SAO however features a four layer PCB. Twinkle Twinkie explains why in his Hackaday entry entitled Controlling Light with Layers.

Twinkle Twinkie summarizes, "If you're designing a board where light will be intentionally shone through the back and if you're looking to control exactly where that light is shown without affecting the top copper layer then you'll need to use inner copper layers to get the results you're looking for."

Assembly of the Peanut Butter SAO Kit exactly parallels the Kuchi Kopi SAO Kit. The notes about LED orientation and hot glue experimentation apply equally here.

Step 13: Disco Backlight SAO Kit

The Disco Backlight SAO magically turns anything with a flat backing into an SAO with cycling RGB color backlighting. The Disco Backlight SAO is exactly 40mm in diameter. Not coincidentally, the same diameter of a standard ceramic/clay casino cheque.

The Disco Backlight SAO can drive up to two RGB Flashing SMD 2835 LEDs. When soldering these, match the larger terminal on the back of the LED (the cathode) to the larger pad on the PCB (GND).

Disco Backlight SAO Kit Assembly:

1. Solder two (or zero, or one) RGB Flashing SMD 2835 LEDs
2. Snap off a 2x3 section of the 2x40 male SMD header
3. Solder the 2x3 header to the pads on the rear of the SAO
4. Attach whatever artifact onto the front side using a 3M double-sided adhesive disc

When using the 2x3 SMD headers, be sure to use plenty of solder at each pin and to achieve excellent solder flow between the pad and the pin. This is important because the SAO header solder joints must mechanically support the SAO.

When applying an oversized vinyl decal, such as the one with the US Cyber Command emblem, try this: Rough cut the decal and apply it onto the PCB. Hold another of the PCBs against the decal forcing it stay flat. Run a razor or XACTO knife along the edge of the PCB sandwich all the way around to smoothly remove the excess decal material. If the decal is black and the cutting operation exposes some white vinyl, simply run the felt tip of a black sharpie around the outside edge of the final cut decal.

Step 14: SMD Challenge SAO Kit

Are you ready for a soldering challenge?

What needs to be done here should be obvious at this point. Be sure to select the correct size and value of resistor or LED for each position as shown in the diagram. The LED cathode (-) terminals go to the right and are marked in green (and an underside arrow) as shown in the LED component list.

If you are able to get three or more of the LEDs working, share a photo of your accomplishment. It is possible to solder the 0402 parts (or even smaller) by hand, but it is not a common or necessary skill.

Note that we've included two of each SMD part used in the challenge so you get two shots at each. DFIU. :)

Step 15: Wi-Fi SAO Kit

This is the world's first ever Wi-Fi SAO (as far as we know).

Wi-Fi SAO Kit Assembly:

1. Solder the two WS2812Bs aligning the triangular corner notch with the similar marking on the PCB
2. Solder the two momentary buttons
3. Solder the ESP8285 ESP-M3 Wi-Fi module
4. Solder the shrouded male SAO header with the keying notch oriented up

USB - Serial Module:

Before wiring up the CH340E module to the Wi-Fi SAO, plug the CH340E module up to your PC and be sure that your OS can see the new USB port. You may need to install a CH340 driver.

Programming the Wi-Fi SAO:

1. Connect the CH340E module to the SAO header (3V3 to 3V3, GND to GND, TX to RX, and RX to TX)
2. Install the Arduino IDE (if necessary)
3. Install the ESP8266 board support package
4. Select Tools > Board > Generic ESP8285 Module
5. Open File > Examples > Basic > Blink
6. Hit the UPLOAD arrow icon
7. Hold down both the RESET and FLASH buttons on the SAO
8. When "Connecting..." appears, release RESET while holding down FLASH
9. When the Writing percentages start updating, you can release FASH as well
10. Once the upload completes, hit RESET again
11. The tiny blue LED just under the ESP8285's antenna will start slowing blinking

Web Server Demo:

1. From Tools > Manage Libraries, install FastLED by Daniel Garcia
2. Grab the file WiFiSAO_WebServer from this page and open it
3. Edit the SSID and Password with your network credentials
4. UPLOAD (steps 6 - 9 above)
5. In Arduino IDE open Tools > Serial Monitor and select 115200 baud
6. Press the RESET button on the Wi-Fi SAO
7. Look for the Host IP address printed to the Serial Monitor
8. Paste that IP address into the URL bar of your web browser

This Wi-Fi SAO probably draws more current on the 3.3V rail than a well-behaved SAO should. This sometimes glitches the addressable LEDs (which prefer 5V anyway). Regardless, it's a fairly robust little toy, especially when running on shore power.

Step 16: Go All In... Live the HackLife

We hope you are enjoying this month's HackerBox adventure into electronics, computer technology, and hacker culture. Reach out and share your success in the comments below or other social media. Also, remember that you can email [e-mail] anytime if you have a question or need some help.

What's Next? Join the revolution. Live the HackLife. Get a cool box of hackable gear delivered right to your mailbox each month. Surf over to HackerBoxes.com and sign up for your monthly HackerBox subscription.