Using electrical conduit for a 3D printer frame

June 12, 2013 By 11 Comments

electrical-conduit-for-cnc-frame

We’re always on the lookout for parts that can be source locally and that don’t cost a bundle. This hack fits both of those criteria. [Lee Miller] came up with a way to use steel electrical conduit as a 3D printer frame. He recently finished building the device seen above, and has been showing it off at Solid State Depot, a Hackerspace in Boulder, Colorado where he is a member.

Look closely at the corners of the frame in this image and you’ll see the 3D printed parts that make up the clamping mechanism. Each has three components that screw together. The two gaps in between each have a rubber ‘O’ ring. When the plastic clamps are screwed together they squeeze the rings which hold the electrical conduit firmly. This also has the side benefit of dampening vibrations.

It’s certainly easy to find this type of conduit which is sold at every home store (and most hardware stores). Just make sure that you check that a piece is straight when you pick it out. The SCAD files for the parts are available from his Github repo.

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Filed Under: 3d Printer hacks Tagged With: , ,

Telegraph sounder clicks out email messages

June 12, 2013 By 6 Comments

telegraph-box-together

[Patrick Schless] is excited to show off the project he took on about nine months ago. After finding an antique telegraph sounder he wired it up to an Arduino to see if he could make it tick. The successful experiment laid the ground work for different hardware that would make it into a morse code email reader.

He doesn’t know much about the background of the old hardware, but driving it is relatively simple. It’s basically a magnetic relay so you need to have a transistor for switching and a flyback diode for protection. Once those components are in place it’s just a matter of toggling a bit. [Patrick] knew he wanted to pull messages from an online source, so he set his Arduino aside and grabbed a Raspberry Pi. It worked like a charm. His plan was to put this on a bookshelf in perpetuity so he went the extra mile, designing his own PCB and having it spun using the OSH Park service. The project is finished with this low-profile laser-cut base which houses all of the electronics.

Now if he wants to respond to his emails in Morse code he needs to build this keyboard.

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Filed Under: radio hacks, Raspberry Pi Tagged With: , , , , ,

Building a WiFi enabled Nixie counter

June 11, 2013 By 13 Comments

wifi-nixie-counter

[Kevin Ballard] built this Nixie counter on the company dime. Tubes like this are getting more and more difficult to find since they’re no longer being manufactured. But when the Bossman hands you a corporate credit card those kinds of concerns take a back seat to your parts-shopping impulses. Start to finished this WiFi enabled counter took six weeks to build.

Connecting the board to the internet was very easy thanks to the Electric Imp that drives it. The difficult part comes in building a driver board and sockets for the tubes. We don’t see a lot of detail on how he’s generating the high voltage. But you can get a good feel for the tube connectors from the picture. He’s using an adapter PCB from Kosbo which breaks the tube pins out to two rows of 0.1″ pitch pin headers. The acrylic base has a port for each made of pin sockets spaced by a thick chunk of acrylic. Wiring harnesses wrap around the back side of the base to mate with the driver hardware. It’s programmed to count some type of company metric (it was funded by the corporation after all). They must be fairly successful because those numbers are flying by in the demo video.

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Filed Under: Microcontrollers Tagged With: , , ,

3D printed hand-cranked digital computer

June 11, 2013 By 15 Comments

3d-printed-digital-computer

What a beautiful thing it is to see this digital computer in action. [Chris Fenton] did an amazing job of designing and printing this mechanical digital computer. If you’re interested in one to call your own check out the source files he published this week.

[Chris'] design inspiration came from some research into Victorian Era mechanical looms. He adjusted the concept to build a punch card reader, starting with a capacity of three holes and moving to this design which can read ten holes. It provides just enough bits to address all three of the counters pictured above. Program the computer by inserting a punch card that is the size of a business card and crank away. The video below shows the process from afar… hopefully he’ll post a follow-up video with closer views of each piece in action.

This isn’t his first basic computing machine. Check out the electromechanical version from last year.

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Filed Under: 3d Printer hacks, computer hacks Tagged With: , ,

60,000 RPM vacuum powered rotary tool was 3D printed

June 11, 2013 By 56 Comments

vacuum-powered-rotary-tool

The whining of the turbines in the 3D printed pneumatic rotary tool might make your teeth hurt. When [Axodus] tipped us off about it he mentioned it sounded like a 747 taking off. But we hear a dentist’s drill when watching the demo video.

[Richard Macfarlane] published his design if you want to try building one for yourself. But you will need to do some machining in addition to printing the enclosure and the pair of turbines. The shaft of the tool needs to fit the bearings precisely. It accepts a center blue spacer with a red turbine on either side. This assembly is encapsulated in the two-part threaded blue body which has a flange to friction fit with the shop vacuum hose. The business end of the machined shaft was designed and threaded to accept the collet from a Dremel or similar rotary tool.

We wonder how much work it would be to re-engineer this to act as a PCB drill press?

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Filed Under: 3d Printer hacks, tool hacks Tagged With: , , , , ,

Automated programming and testing jig built with Raspberry Pi

June 10, 2013 By 5 Comments

automated-programming-testing-rig-built-from-RPi

[Doug Jackson] makes word clocks, and he must be doing quite a bit of business. We say that because he put together a programming and test bed for the clock circuit boards.

This is a great example to follow if you’re doing any kind of volume assembly. The jig lets the populated PCB snap into place, making all the necessary electrical connections. This was made possible by a package of goods he picked up on eBay which included rubber spacers to separate the board from the acrylic mounting plate, pogo pins to make the electrical connections, and a spring-loaded board clamp seen to the left in this image.

The switch in the lower right connects power to the board and pulls a Raspberry Pi GPIO pin high. The Python script running on the RPi polls that pin, executing a bash script which programs the ATmega169 microcontroller using the GPIO version of AVRdude. We looked through his Python script and didn’t see code for testing the boards. But the image above shows a “Passed” message on the screen that isn’t in his script. We would wager he has another version that takes the hardware through a self test routine.

We first saw one of [Doug's] word clocks back in 2009 and then again a few months later. The look of the clock is fantastic and it’s nice to see the project is still going strong.

Filed Under: Microcontrollers, Raspberry Pi Tagged With: , , , , , ,

Gesture control uses WiFi doppler shift

June 10, 2013 By 29 Comments

wifi-gesture-control

We’ve said it before: in the future simple interfaces will use nothing but your body. At least at first glance that’s the case with this WiFi-based gesture control system. If you have Internet at home you probably have a WiFi access point. That’s the first portion of the equation. The remainder is a way of measuring how the radio waves bounce off of your body. So far this is being done with Software-Define Radio (SDR) but researchers at University of Washington think it may be possible to build the technique into future WiFi devices.

The demo video shows this man waving his arm to adjust the volume of his home entertainment system. Intuition tells us that this would be impossible if your arm wasn’t the only thing in motion at the time. But that issue is quickly addressed. Multiple antennas can track multiple people at the same time. There is also consideration for false-positives. The system requires a moderately complex wake-up gesture sequence to prevent you from, say, accidentally turning on the stereo when you roll over in bed.

If you’re having trouble wraping your mind around this, consider this ultrasonic music player. The WiFi version does the same thing, but processing changes in the returning radio waves is much more complex.

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Filed Under: peripherals hacks Tagged With: , , , ,
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