The coffee maker which [Donald Papp] uses every morning has a water reservoir on the back that can last for several days. This means he forgets to check it and from time to time will return to find that nothing has brewed. He decided to add a low-water indicator to the machine. His approach is about as simple as it gets and we admire that accomplishment.
If it were our project we’d probably try to complicate it in one way or another. The use of a microcontroller and ultrasonic rangefinder (like this tank level indicator from a February links post) would be overkill. No, [Donald] boiled down the electronics to a homemade switch, a blinking LED, and a battery. The switch is a flexible piece of metal attached to a plastic cap using some monofilament. The cap goes in the reservoir and floats until the water gets too low, it then pulls on that metal, completing a circuit between the battery and the LED. That’s it, problem solved.
Now he just needs to plumb the coffee maker into a water line and he’ll really be set.
Turning 3D printed plastic parts into metal objects is not a new concept. But we don’t see a lot of it and enjoyed watching the documentary version of [3DTOPO’s] lost PLA metal casting process so much we figured you’d want to see it too.
The thirty-five minute video walks through every part of the process which we originally learned about in September of last year. The process was developed as a way to fabricate parts that will be used in high-stress applications. For instance, the part seen above is a mounting bracket for the ball screws that moves the Z axis on a huge CNC build he’s been working on. A plastic part will break under the strain so he needed to make it out of aluminum alloy.
To start, the piece is modeled and printed in plastic to check the fit. Once it’s just right he scales it to 103% and prints it again to account for the shrinking of the metal as it cools. The next step is pictured above, adding paths using rigid foam insulation that allow for the metal pour and for air to escape. This is packed into a plaster and sand mold which dries before being cooked in a furnace to vaporize the foam and PLA. This leaves a perfect mold for the metal pour.
After the break you can see a 5-minute overview version of the project.
Continue reading “Update: lost PLA metal casting — The Movie”
This is a fascinating concept. We’re not sure of its usefulness, but it definitely stands on its own just for the concept. [Dean Camera] just added a new HID class to the LUFA project that lets you flash AVR chips by printing to them. This means once you have a file like the one seen open in Notepad above, you can just click on File, then on Print, and the firmware will be uploaded to the chip.
[Dean] is the creator of the LUFA project and still likes to get his hands dirty hacking around with it. This idea came to him while he was exploring the concept of using the MIDI protocol to program a chip. That didn’t pan out because of the way Microsoft has handled MIDI in newer versions of Windows. But he did get the idea of making LUFA identify itself as a simple USB printer. He dug into the specification and figured out how to do that. Once Windows connects to the device it doesn’t really care what data gets sent to it. So [Dean] wrote a parser for the bootloader which could accept the incoming hex code and write it to the chip’s program memory.