Hacklet 57 – CNC Hacks

Everyone’s first microcontroller project is making an LED blink. It’s become the de-facto “Hello World” of hardware hacking.  There’s something about seeing wires you connected and the code you wrote come together to make something happen in the real world. More than just pixels on a screen, the LED is tangible. It’s only a short jump from blinking LEDs to making things move. Making things move is like a those gateway drug – it leads to bigger things like robots, electric cars, and CNC machines. Computer Numerical Control (CNC) is the art of using a computer to control movement. The term is usually applied to machine tools, which cut, engrave, or perform other operations on wood, plastic, metal and other materials. In short, tools to make more things. It’s no surprise that hackers love CNCs. This week’s Hacklet is all about some of the best CNC projects on Hackaday.io!

charliexWe start with [Charliex] and Grizzly G0704 CNC Conversion. [Charliex] wanted a stout machine capable of milling metal. He started with a Grizzly  G0704, which is small compared to a standard knee mill, but still plenty capable of milling steel. [Charliex] added a Flashcut CNC conversion kit to his mill. While they call them “conversion kits” there is still quite a bit of DIY ingenuity required to get a system like this going. [Charliex] found his spindle runout was way out of spec, even for a Chinese mill. New bearings and a belt conversion kit made things much smoother and quieter as well. The modded G0704 is now spending its days cutting parts in [Charliex’s] garage.


makesmithNext up is [brashtim] with Makesmith CNC. Makesmith was [brashtim’s] entry in the 2014 Hackaday prize. While it didn’t win the prize, Makesmith did go on to have a very successful Kickstarter, with all the machines shipping in December of 2014. The machine itself is unorthodox. It uses closed loop control like large CNC machines, rather than open loop stepper motors often found in desktop units. The drive motors are hobby type servos.  We’re not talking standard servos either – [brashtim] picked microservos. By using servos, common hardware store parts, and laser cut acrylic, [brashtim] kept costs down. The machine performs quite well though, easily milling through wood, plastic, foam, and printed circuit boards.


reactronNext we have [Kenji Larsen] with Reactron material processor: Wireless CNC mill. [Kenji] started with a  Shapeoko 2, and gave it the Reactron treatment. The stock controller was replaced with a Protoneer shield, which is connected to the Reactron network via a HopeRF radio module. The knockoff rotary tool included with the kit was replaced with a DeWalt DW660 for heavy-duty jobs, or a quieter Black and Decker RTX-6. A tool mounted endoscope keeps an eye on the work. [Kenji] mounted the entire mill in a custom enclosure of foam and Roxul insulation. The enclosure deadens the sound, but it also keeps heat in. [Kenji] plans to add a heat exchanger to keep things cool while maintaining relative quiet in his shop.

cnc2Finally we have a [hebel23] with DIY Multiplex Plywood CNC Router. [hebel23] wanted to build a big machine within a budget – specifically a working area of  400 x 600 x 100 mm and a budget of 800 Euro. As the name implies, [hebel23] used birch plywood as the frame of his machine. He chose high quality plywood rather than the cheap stuff found in the big box stores. This gives the machine a stable frame. The moving components of the machine are also nice – ball screws, linear bearings, and good stepper controllers. The stepper motors themselves are NEMA-23 units, which should give the CNC plenty of power to cut through wood, plastic, and even light cuts on metal. [hebel23] spent a lot of time on the little details of his CNC, like adding an emergency stop switch, and a wire-chain to keep his gantry control wires from ending up tangled up in the work piece. The end result is a CNC which would look great in anyone’s workshop.

If you want more CNC goodness, check out our brand new CNC project list! Did I miss your project? Don’t be shy, just drop me a message on Hackaday.io. That’s it for this week’s Hacklet, As always, see you next week. Same hack time, same hack channel, bringing you the best of Hackaday.io!

Quantum Mechanics in your Processor: Complementarity

Monday | 24 October 1927 | Brussels

While the official title of the 5th Solvay conference was “on Electrons and Photons”, it was abundantly clear amongst the guests that the presentations would center on the new theory of quantum mechanics. [Planck], [Einstein], [Bohr], [de Broglie], [Schrodinger], [Heisenberg] and many other giants of the time would be in attendance. Just a month earlier, [Niels Bohr] had revealed his idea of complementarity to fellow physicists at the Instituto Carducci, which lay just off the shores of Lake Como in Italy.

The theory suggested that subatomic particles and waves are actually two sides of a single ‘quantum’ coin. Whichever properties it would take on, be it wave or particle, would be dependent upon what the curious scientist was looking for. And asking what that “wave/particle” object is while not looking for it is meaningless. Not surprisingly, the theory was greeted with mixed reception by those who were there, but most were distracted by the bigwig who was not there – [Albert Einstein]. He couldn’t make it due to illness, but all were eager to hear his thoughts on [Bohr’s] somewhat radical theory. After all, it was he who introduced the particle nature of light in his 1905 paper on the photoelectric effect, revealing light could be thought of as particles called photons. [Bohr’s] theory reconciled [Einstein’s] photoelectric effect theory with the classical understanding of the wave nature of light. One would think he would be thrilled with it. [Einstein], however, would have no part of [Bohr’s] theory, and would spend the rest of his life trying to disprove it.

Complementarity – Wave , Particle or both?

einstein and bohr
[Niels Bohr] contemplates one of [Einstein’s] many challenges to quantum theory.
For more than a century it was thought that light was a wave. In 1801, [Thomas Young] had discovered interference patterns when shining a light through two very close slits. Interference is a well known property of waves. This combined with [Maxwell’s] equations, which predicted the existence of electromagnetic radiation put little doubt into anyone’s mind that light was nothing more, or less, than a wave. There was a very odd issue, however, that puzzled physicists during the 18th century. When shining light upon a metallic surface, electrons would be ejected from that surface. Increasing the intensity of the light did not translate to an increase in speed of the expelled electrons, like classical mechanics says it should. Increasing the frequency of the light did increase the speed. The explanation of this phenomenon could not be had until 1900, when [Max Planck] realized that physical action could not be continuous, but must be a multiple of some small quantity. This quantity would lead to the “quantum of action”, which is now called [Planck’s] constant and birthed quantum physics. It would have been impossible for him to know that this simple idea, in less than two decades, would lead to a change in understanding of the nature of reality. It only took Einstein, however, a few years to use [Planck’s] quantum of action to explain that mind-boggling issue of electrons releasing from metal via light and not following classical law with the incredibly complex equation:

E = hv

Where E is the energy of the light quanta, h is Planck’s constant and v is the frequency of the light.  The most important item to consider here is this light quanta, later to be called a photon.  It is treated as a particle. Now, if you’re not scratching your head in confusion right about now, you haven’t been paying attention. How can light be a wave and a particle? Join me after the jump and we’ll travel further down this physics rabbit hole.

Continue reading “Quantum Mechanics in your Processor: Complementarity”

Caption CERN Contest – What’s In The Box?

Week 24 of the Caption CERN Contest was one for the books. There were so many good captions that we had a hard time picking a winner! Thank you to everyone who wrote up a caption and entered the contest. We still don’t know quite what this device was. Our best guess is a coil from a beam line. Some creative positioning and camera focus sure turned it into a conversation piece though!

The Funnies:

  • “I am the Face of Boe. Has anyone seen the Doctor?.” – [jonsmirl]
  • “CERN’s brief attempt into the consumer “Pro” audio market. They lost out to the competitions because they didn’t use unidirectional oxygen free copper wires that are blessed by the Tibetan monks. They might be the expert with super conductor magnets, but one hard lesson they have learnt is that you can’t spell consumer without the “con” part.” – [K.C. Lee]
  • “Go ahead pick up the operating tool!! For your first task remove the patient’s tooth for 10 points. But beware!!! there’s the 10,000K volt charge if you touch the sides!! Enjoy!!!” – [EngineerAfterLunchTime]

This week’s winner is [surubarescu] with “Prototype of the sextuple face electric razor was a complete technical success, but it never went into full production due to some raised (then lost) eyebrows.” Enjoy your new Teensy 3.1 from The Hackaday Store, [surubarescu]!

Week 25

cern-25-smWe’re not kidding when we say CERN scientists and engineers really get into their work. Check out this CERN scientist looking down at his… uh, experiment. We’re not sure exactly what this device is. There is a sealed chamber, but is it a vacuum, or some sort of specialized atmosphere for the research this scientist is working on? Either way, he seems very interested in whatever is happening inside this box!

So what’s happening here? High energy physics, or some new coffee maker? You tell us!

This week’s prize is once again a Teensy 3.1 from The Hackaday Store. Add your humorous caption as a comment to this project log. Make sure you’re commenting on the contest log, not on the contest itself.

As always, if you actually have information about the image or the people in it, let CERN know on the original image discussion page.

Retrotechtacular: Coopering Guinness Barrels by Hand

For almost exactly 200 years, the Guinness brewery in Dublin, Ireland employed extremely skilled craftsmen to shape and construct wooden casks by hand. These men were called coopers, and plying their trade required several years of apprenticeship. The cooperage was a kind of closed society as many of the positions were passed down through generations of families. With the rise of aluminium and then stainless steel barrels in the late 1950s, the master coopers of Guinness became a dying breed.

Almost every step of the coopering process shown in this film is done without any kind of precise measurement. A master cooper like [Dick Flanagan] here needs only his eyes and his practiced judgment. His barrels start out as oak planks called ‘staves’ that have been drying in racks for at least two years. A cooper selects the staves that strike his fancy and he saws off the ends. This seems to be the only part of the process where a power tool is used.

The cooper shapes each stave by hand with axe and adze so that its ends are tapered just so. Once he has shaped enough of them to make a barrel, he arranges them in a cylinder around the inside of a metal band known as a hoop. The bound staves are steamed for half an hour to make them pliable enough for shaping.

After steaming, the splayed end of the staves are bound with wire rope to pull them close enough together that a hoop can be fitted over them. The inside of the cask is then charred with burning oak shavings, a process that seals the wood and removes its acidity. After this, the ends are sanded and the bunghole is drilled.

For each barrel, the cooper crafts a custom set of hoops. These are installed after the outside of the barrel has been shaved smooth. Finally, the heads that cap each end of the cask are made from more oak staves held together with dowel rods. This is the only time the cooper uses a tool to measure anything, and he does so to achieve the proper circumference on the heads. He bevels the edges so the heads will fit into bored-out grooves in the cask walls. Once they’re seated, the keg is ready for dark, rich stout.

Continue reading “Retrotechtacular: Coopering Guinness Barrels by Hand”

Hackaday Links: July 19, 2015

Everybody needs an external USB drive at some time or another. If you’re looking for something with the nerd cred you so desperately need, build a 5 1/4″ half height external drive. That’s a mod to an old Quantum Bigfoot drive, and also serves as a pretty good teardown video for this piece of old tech.

The Woxun KG-UV2D and KG-UV3D are pretty good radios, but a lot of amateur radio operators have found these little handheld radios eventually wear out. The faulty part is always a 24C64 Flash chip, and [Shane] is here to show you the repair.

Last year there was a hackathon to build a breast pump that doesn’t suck in both the literal and figurative sense. The winner of the hackathon created a compression-based pump that is completely different from the traditional suction-based mechanism. Now they’re ready for clinical trials, and that means money. A lot of money. For that, they’re turning to Kickstarter.

What you really need is head mounted controls for Battlefield 4. According to [outgoingbot] it’s a hacked Dualshock 4 controller taped to a bike helmet. The helmet-mounted controller has a few leads going to another Dualshock 4 controller with analog sticks. This video starts off by showing the setup.

[Jan] built a modeling MIDI synth around a tiny 8-pin ARM microcontroller.  Despite the low part count, it sounds pretty good. Now he’s turned his attention to the Arduino. This is a much harder programming problem, but it’s still possible to build a good synth with no DAC or PWM.

Caption CERN Contest – Smile!

Week 23 of the Caption CERN Contest has been laid to rest. Thanks to all the entrants who stopped by to pay their respects and leave captions for the dearly departed SC-1. CERN engineers and scientists are a crafty bunch, so we’re betting that SC-1’s spirit (and many if its components) lived on in newer CERN projects. We have to thank CERN’s unnamed photographer for capturing these events. It’s always great to see the people and the personalities behind the science.

The Funnies:

  • “After many years of ignoring the pitiful meows, it was finally determined that Schrödinger’s cat was, in fact, dead.” – [Josh Kopel]
  • “We gather here to mourn the deaths of all those brave and noble components that left this world surrounded by magic smoke to reside forever in great the parts bin in the sky.” – [Kid Iccurus]
  • “CERN’s annual Halloween parade was a huge disappointment that year, which was probably due to the fact that they held it in June.” – [DainBramage]

This week’s winner is [Scott Galvin] with “Services were held today for SC-1. SC1’s life ended earlier
this week after a devastating head on collision” Scott describes himself as “Just a visiting Geek with dreams of universal domination”. We’d suggest you start small, [Scott]. Maybe dominating a Bluetooth personal area network with your new LightBlue Bean from The Hackaday Store is just what you need to set your plans in motion!

Week 24

cern-24-smThe scientists at CERN always take a personal stake in their work. Pushing mankind’s knowledge of science and high energy physics takes a special breed of person. Thankfully this special breed always seems to have a fun side as well. Here we see a CERN scientist posing behind a … a device. It looks to be some kind of coil or beam line part, though the actual use is thus far a mystery even to CERN’s own staff. We do know this photo was taken in June of 1973, the same month as one of the longest solar eclipses on record – over 7 minutes of totality! Was this part of some CERN solar experiment? Could it have been a section of a particle accelerator? Was this scientist just working on his latest art project – perhaps part of a dodecagon exploration? You be the judge!

This week’s prize is a Teensy 3.1 from The Hackaday Store. Add your humorous caption as a comment to this project log. Make sure you’re commenting on the contest log, not on the contest itself. As always, if you actually have information about the image or the people in it, let CERN know on the original image discussion page.

Hacklet 56 – Brain Hacks

The brain is the most powerful – and least understood computer known to man. For these very reasons, working with the mind has long been an attraction for hackers, makers, and engineers. Everything from EEG to magnetic stimulus to actual implants have found their way into projects. This week’s Hacklet is about some of the best brain hacks on Hackaday.io!

teensy-bio[Paul Stoffregen], father of the Teensy, is hard at work on Biopotential Signal Library, his entry in the 2015 Hackaday Prize. [Paul] isn’t just hacking his own mind, he’s creating a library and reference design using the Teensy 3.1. This library will allow anyone to read electroencephalogram (EEG) signals without having to worry about line noise filtering, signal processing, and all the other details that make recording EEG signals hard. [Paul] is making this happen by having the Teensy’s cortex M4 processor perform interrupt driven acquisition and filtering in the background. This leaves the user’s Arduino sketch free to actually work with the data, rather than acquiring it. The initial hardware design will collect data from TI ADS129x chips, which are 24 bit ADCs with 4 or 8 simultaneous channels. [Paul] plans to add more chips to the library in the future.


bioxNext up is [Jae Choi] with Lucid Dream Communication Link. [Jae] hopes to create a link between the dream world and the real world. To do this, they are utilizing BioEXG, a device [Jae] designed to collect several types of biological signals. Data enters the system through several active probes. These probes use common pogo pins to make contact with the wearer’s skin. [Jae] says the active probes were able to read EEG signals even through their thick hair! Communication between dreams and the real world will be accomplished with eye movements. We haven’t heard from [Jae] in awhile – so we hope they aren’t caught in limbo!

bioloop[Qquuiinn] is working from a different angle to build bioloop, their entry in the 2015 Hackaday Prize. Rather than using EEG signals, [Qquuiinn] is going with Galvanic Skin Response (GSR). GSR is easy to measure compared to EEG signals. [Qquuiinn] is using an Arduino Pro Mini to perform all their signal acquisition and processing. This biofeedback signal has been used for decades by devices like polygraph “lie detector” machines. GSR values change as the sweat glands become active. It provides a window into a person’s psychological or physiological stress levels. [Qquuiinn] hopes bioloop will be useful both to individuals and to mental health professionals.

biomonitorFinally we have [Marcin Byczuk] with Biomonitor. Biomonitor can read both EEG and electrocardiogram (EKG) signals. Unlike the other projects on today’s Hacklet, Biomonitor is wireless. It uses a Bluetooth radio to transmit data to a nearby PC or smartphone. The main processor in Biomonitor is an 8 bit ATmega8L. Since the 8L isn’t up to a lot of signal processing, [Marcin] does much of his filtering the old fashioned way – in hardware. Carefully designed op-amp based active filters provide more than enough performance when measuring these types of signals. Biomonitor has already found it’s way into academia, being used in both the PalCom project, and brain-computer interface research.

If you want more brain hacking goodness, check out our brain hacking project list! Did I miss your project? Don’t be shy, just drop me a message on Hackaday.io. That’s it for this week’s Hacklet, As always, see you next week. Same hack time, same hack channel, bringing you the best of Hackaday.io!