Changing Nozzle Internal Geometry To Increase FDM Flowrate

September 10, 2026 by 3 Comments

As FDM printers keep getting faster, we are forced to deal with a range of bottlenecks, all of which conspire to hold us back from another Benchie world record. A major physical limitation is that of flowrate, as the hotend has to be able to melt the filament that enters the nozzle before it departs said nozzle. One attempt to make a high-flow nozzle involves splitting the material path into three winding sections, which theoretically should help said flowrate. Recently [Thomas Sanladerer] took a poke at this and other types of nozzle with SLS-printed nozzles.

These printed parts still needed some finishing on the lathe, including drilling the 0.4 mm nozzle hole. The finished nozzles feature a variety of internal geometries, including the aforementioned triple-path, as well as many with various intrusions that seek to maximize the contact area.

Using a Prusa Core One these nozzles were subsequently tested to see what print quality they produced at high flow rates. A special test rig to test the nozzle pressure was also used to further characterize them, as this indicates at which flowrate the nozzle begins to struggle. Among these the Fuge design did the best, though with the big asterisk that these nozzles were printed in MS1, which is in effect tool steel and thus not great for being nozzles.

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Creating A Custom Hinge For A Motorbike’s Fuel Access Panel

September 10, 2026 by No comments

A fun part of modifying something like a motorbike is that you sometimes have to come up with creative solutions to basic questions, like how you can still access the fuel tank’s cap after extending it forward. In the case of [KRTframework] this meant that the fuel cap was now underneath the bodywork, requiring a suitable way to access it. Of course, this meant making a hidden access panel with a custom hinge, to not break the bike’s clean lines.

To make the process as easy as possible, a 3D scanner was used to get detailed measurements on what the new bodywork would look like. Using these the new bodywork was created, including what would be the hidden access panel, yet finding a suitable hinge mechanism wasn’t easy. This is where this custom design was created, with detailed assembly covered in the video.

To bridge the gap between the opening and the fuel tank a part was 3D-printed that also contains the simple push-to-open latch mechanism. Of course, in the comment section people sounded off on this, feeling that it would be far too easy to accidentally open the panel.

The hinge seems to be well-received at least, with it having to fit within the available space, while also providing good access to the fuel cap when opened, meaning quite a lot of travel.

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Little Droid Has Party Mode

September 10, 2026 by 5 Comments

Remember those tiny little droids skittering around the pristine corridors of the Death Star in Star Wars? [heychaostheory] has put together something vaguely along the lines of those charming little mobile toasters. It’s an autonomous mouse droid with party mode!

The build is interesting in that it’s based on an off-the-shelf metal robot chassis—which provides mounting points for the gearmotors and wheels that make up the drivetrain. The mouse droid body sits atop this, being a 3D printed part that is afixed with heat set inserts and nylon standoffs. It’s 3D printed and expertly decorated with a fun vibe. Inside the body lives an Arduino Uno, hooked up to an L298 motor driver board and ultrasound sensors used for obstacle avoidance. It’s also got a smattering of LEDs to flash, because blinkenlights matter. The best bit, though, is the party mode button, which fires off music via a DFPlayer Mini module.

The mouse droid may not be as flashy and imposing as the Droideka or as mechanically impressive as BB-8, but that just makes it more accessible and fun to build. You can easily create one at full scale without breaking the bank. If you’re cooking up your own fun droids in the workshop, don’t hesitate to let us know. Video after the break.

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3D Imaging Without A Lens

September 10, 2026 by 9 Comments

There are plenty of ways to capture 3D images or simulations of such if you know what you’re doing with camera hardware and fancy mathematics. However, a little more unusual is the idea of capturing a 3D image while using no lens at all — and yet, [okooptics] has achieved just that!

The basic concept builds on an older project from [okooptics], wherein images were captured from a Raspberry Pi camera with no regular lens element installed. In its place was a thin layer of Scotch tape over the sensor, acting as a diffuser. With the right deconvolution math, it’s possible to actually recover a real image out of the blurry mess this setup initially captures. [okooptics] was then able to push this into three dimensions by weighting the point spread function used to deconvolute the image.

Adding directional bias to the process creates a similar effect to slightly shifting the cameras position, actually revealing a view from a slightly different angle of objects in front of the camera. [okooptics] does a great job of explaining the science behind how this is possible and the practical limitations of the technique, also referencing research papers that have explored these ideas in great depth.

It’s math heavy to extract 3D data from what otherwise looks like blurry nothingness, but it’s possible if you know what you’re doing. For a fuller understanding, it’s worth diving into [okooptics] earlier work in this realm, taking photos with Scotch tape in place of a lens.

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Custom AMOLED Wearable Makes Great Icebreaker

September 10, 2026 by 6 Comments

Nifty little AMOLED screens are easy to get nowadays, and [Sophie D] demonstrates they are both thin and light enough to be worn with OpenChoker, a design for a choker necklace that was a hit at DEF CON.

The choker consists of an AMOLED touchscreen flanked by short RGB LED strips. Behind the display is the PCB which contains an RP2350 and micro SD card slot for external storage, and at the rear of the choker is an 18650 cell to power it all. The display plays an eye-catching animation that gets generated on the fly while the LEDs sparkle away.

[Sophie] shares a number of interesting takeaways from designing and building this device. One is that the bulk of the PCB design work was interfacing to the display, since no existing footprint or reference design could be found. So if you find yourself with a Hello Lighting HL020E21-02 2.14″ touchscreen display you’re hankering to use in your own project, do yourself a favor and check out [Sophie]’s board design instead of starting from scratch.

Battery life was more than enough for a device like this. A single 18650 cell powered the choker effortlessly for a 16-hour stretch and still the cell measured a robust 3.7 V. While a light-up choker used indoors isn’t a great candidate for wearable solar power, it’s encouraging that there’s no need for a tethered battery pack.

Another tip to consider relates to the screen’s touch sensitivity. In short, the capacitive touch screen responded perfectly when plugged into a development computer, but when mounted and isolated on the choker it responded so poorly as to be useless. It didn’t keep the rest of the choker from doing its job, but it might be worth keeping in mind as something to watch out for with a device like this.

There’s one final mystery [Sophie] ran into: with only one day to spare, glue used to affix some wires ended up melting away the wire insulation, revealing bare copper. We’re not sure what happened there, but if nothing else it’s a reminder that Murphy’s Law is always ready to strike when one is on a deadline.

Tech In Plain Sight: Meet The Robot That Does CPR

September 10, 2026 by 12 Comments

Usually in Tech In Plain Sight, we talk about technology you probably see every day, even if you don’t notice it. But we hope you don’t get to see one of the latest crop of medical robots, such as the LUCAS chest compression system. If you watch the popular TV series “The Pitt”, though, you may have caught a glimpse of one of these medical marvels. They aren’t fiction. They are very real devices.

Calling them robots might be stretching the definition a little. They don’t roam the halls looking for patients. But once attached to someone in cardiac arrest, they can take over one of the most important — and physically demanding — parts of CPR: chest compressions.

Keep The Blood Moving

When someone’s heart stops pumping blood, time is critical. CPR doesn’t normally restart the heart on its own. Instead, chest compressions produce enough blood flow to keep oxygen reaching the brain and heart while rescuers work on the underlying problem and, when appropriate, use a defibrillator.

Doing that well is harder than it looks on television. Current American Heart Association guidelines call for adult chest compressions 100 to 120 times per minute, at least 5 cm deep but generally no deeper than 6 cm, while allowing the chest to recoil fully between compressions. Interruptions should be kept to a minimum.

That’s hard physical work. In fact, studies show compression depth begins to fall after only about 90 to 120 seconds, which is one reason CPR teams normally swap compressors every two minutes. But a robot doesn’t get tired.

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Open Source Acoustic Drone Detection

September 10, 2026 by 18 Comments

Drones have become a potent military threat, particularly on the small scale. Nimble multi-rotor drones are fast, difficult to spot, and can cause plenty of harm if allowed to go about their work unhindered. The first step to dealing with this issue is detection—a problem that [Agam Rossen] has put some work into.

The result is VolAnti—an open-source drone detector. This route was chosen as a reliable way to detect incoming multi-rotors, since spinning propellers tend to create a telltale sound that can be plucked from the noise quite specifically. In a world where fiber optic drones eschew RF emissions, it also proves particularly useful for early warning of such craft.

VolAnti relies on a small four-microphone array, with the I2S output of all four mics summed together. The output is then fed into a 2048-point FFT running every 32 ms on an ESP32-S3. A comb score is given to try and pick out different blade rates from 70 Hz to 2000 Hz. Multiple detection algorithms run in parallel, because [Agam] noted a problem—using an adaptive noise floor would miss drones that arrived in the area and hovered in place. With the noise not varying, it would get filtered out by the adaptive floor, so one algorithm in the four runs with no floor to catch drones that aren’t moving. Files are on GitHub for those curious to learn more.

We’ve featured other acoustic detection projects before, too. If you’re working on something similar, or conversely, you have the inside scoop on how to hide a drone’s noise signature, don’t hesitate to let us know on the tipsline.

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