Making of the BSides SF Astronaut Badge
summary
Full-color astronaut badge built as a single-sided PCB with components on the back, UV-printed artwork and lacquer gloss, powered by a coin cell and micro USB for CTF access; LED backlighting uses LEDs soldered upside-down to glow through the front. Process specifics: UV printer ($15,000), masked white/black layers to stabilize color and register the print, detailed reflow oven profiling to find a temperature sweet spot that avoids yellowing, run ~250 badges at roughly $25 per unit, and the badge CTF and hardware both work.
AI-written summary · about
chapters (9)
- 0:00Introduction and speaker intro
- 0:43Speaker background and badge history
- 3:16Badge theme and CTF concept
- 7:35Prototype challenges and fixes
- 12:15PCB components and design choices
- 14:46SEO design and LED experimentation
- 16:33CTF setup and accessibility
- 19:03Badge Village and distribution details
- 20:31Q&A and cost discussion
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