Only 90s Kids Will Appreciate This Prototype

[Madox] is a trackball user, which is fine; we at Hackaday respect and appreciate those who live alternative lifestyles. As you would expect, there aren’t many makes and models of trackballs being sold, and [Madox] wanted something ergonomic. A DIY solution was necessary, but how to you model something ‘ergonomic’ before printing it out? Floam, apparently.

Highly advanced 3D prototyping skills

Floam is a sticky, moldable goo originally sold as the follow-up to Nickelodeon’s Gak in the early 1990s. It consists of styrofoam pellets held together with a colored binder that doesn’t leave a mess and doesn’t dry out. While the Nickelodeon version is lost to the sands of time, a Floam-like substance is available at any toy store. [Madox] picked up a few blister packs and began modeling his ideal trackball.

With the proper shape in hand, [Madox] needed a way to get this design into a computer. Photogrammetry is the solution, and while earlier experiments with Autodesk Catch were successful, Autodesk has morphed and rebranded their photogrammetry software into Autodesk ReMake. Turing a pile of styrofoam balls into a 3D model is as simple as taking a bunch of pictures and uploaded to Autodesk’s ‘cloud’ service.

In just a few minutes, a proper 3D mesh arrived from the Autodesk mothership, and [Madox] took to importing this model into Fusion 360, fiddling with chamfers, and eventually got to the point where a 3D printer was necessary. It took a few revisions, but now [Madox] has a custom designed trackball that was perfectly ergonomic.

Tightwad Hacks Label Printer, Beats Manufacturer at Own Game

Sometimes we hack for the thrill of making something new, and sometimes we hack to push back the dark veil of ignorance to shed fresh light on a problem. And sometimes, like when turning a used label printer into a point-of-sale receipt printer, we hack because we’re cheapskates.

We say that with the utmost respect and affection — there’s nothing to be ashamed of when your motive is strictly pecuniary. In [Dan Herlihy]’s case, hacking a cheap Brother label printer to use thermal paper meant saving $300 on a dedicated receipt printer. But it also meant beating Brother at their “Razor and Blades” business model that keeps you buying their expensive proprietary labels. A pattern of holes in the plastic label roll tells the printer what size labels are loaded, so [Dan] defeated that by breaking off a piece of the plastic and gluing it on the sensor. To convince the printer that plain thermal paper is label stock, he printed up a small strip of paper with the same pattern of black registration stripes that appear on the back of the labels. Pretty clever stuff, and it lets him print high-resolution receipts for his electronics shop on the seriously cheap.

[Dan]’s hack is simple, but may suffer from wear on the paper encoder strip. Perhaps this Brother hack using the gears as encoders will provide some inspiration for long-term fix.

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DIY USB Power Bank

USB power banks give your phone some extra juice on the go. You can find them in all shapes and sizes from various retailers, but why not build your own?

[Kim] has a walkthrough on how to do just that. This DIY USB Power Bank packs 18650 battery cells and a power management board into a 3D printed case. The four cells provide 16,000 mAh, which should give you a few charges. The end product looks pretty good, and comes in a bit cheaper than buying a power bank of similar capacity.

The power management hardware being used here appears to be a generic part used in many power bank designs. It performs the necessary voltage conversions and manages charge and discharge to avoid damaging the cells. A small display shows the state of the battery pack.

You might prefer to buy a power bank off the shelf, but this design could be perfect solution for adding batteries to other projects. With a few cells and this management board, you have a stable 5 V output with USB charging. The 2.1 A output should be enough to power most boards, including Raspberry Pis. While we’ve seen other DIY Raspberry Pi power banks in the past, this board gets the job done for $3.


The Tiniest Mechanical Keyboard Ever

Owning a mechanical keyboard makes you a better person. It puts you above everyone else. Of course, owning a mechanical keyboard does come with some downsides. Carrying a mechanical keyboard around all the time to tell everyone else you’re better than them is usually impractical, but [cahbtexhuk Joric] has come up with a solution. It’s a miniature Bluetooth mechanical keyboard that’s also a keychain.

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The Princess and the HDD: Poor Design Choices

You’ll all remember my grand adventure in acquiring a photocopier. Well, it’s been a rollercoaster, I tell ya. While I still haven’t found a modification worthy enough to attempt, I have become increasingly frustrated. From time to time, I like to invite my friends and family over for dinner, and conversation naturally turns to things like the art on the walls, the fish in the aquarium, or perhaps the photocopier in the living room. Now, I dearly love to share my passions with others, so it’s pretty darned disappointing when I go to fire off a few copies only to have the machine fail to boot! It was time to tackle this problem once and for all.

When powered up, the photocopier would sit at a “Please Wait…” screen for a very long time, before eventually coughing up an error code — SC990 — and an instruction to call for service. A bunch of other messages would flash up as well; Address Book Data Error, Hard Drive Data Error, and so on. In the end I realized they all centered around data storage.

Pictured: the author, in his happy place, at peace with the copier.

Now, I’d already tried diving into the service menu once before, and selected the option to format the hard drive. That had led to the problem disappearing for a short period, but now it was back. No amount of mashing away at the keypad would work this time. The format commands simply returned “Failed” every time. What to do next? You guessed it, it was time for a teardown!

Thankfully, photocopiers are designed for easy servicing — someone’s paying for all those service calls. A few screws and large panels were simply popping off with ease; completely the opposite of working on cars. Spotting the hard drive was easy, it looked like some sort of laptop IDE unit. With only SATA laptops around the house to salvage parts from, I wasn’t able to come up with something to swap in.

A bit of research (and reading the label) taught me that the drive was a Toshiba MK2023GAS/HDD2187. Replacements were available on eBay, but if I waited two weeks I’d probably be wrist deep in some other abandoned equipment. It had to be sorted on the night. In the words of [AvE], if you can’t fix it… well, you know how it goes. I yanked the drive and, lo and behold – the copier booted straight up! Just to be sure I wasn’t hallucinating, I churned out a few copies, and other than the continued jamming on all-black pages, everything was fine. Literally all it took to get the copier to boot was to remove the ailing drive. Suffice to say, I was kind of dumbfounded.

The hard drive a.k.a. the villain of the piece.

I’m happy to chalk up the win, but I have to draw issue with Ricoh’s design here. The copier is clearly capable of operating perfectly well without a hard drive. It will give up its document server and address book abilities, but it will still make copies and print without a problem.

Yet, when the copier’s drive fails, the unit fails completely and refuses to work. This necessitates a service call for the average user to get anything at all happening again — causing much lost work and productivity. A better design in my eyes would have the copier notify users of the lost functionality due to the failed drive and the need to call service, but let them copy! Any IT administrator will know the value of a bodged work around that keeps the company limping along for the day versus having a room of forty agitated workers with nothing to do. It’s a shame Ricoh chose to have the photocopier shut down completely rather than valiantly fight on.

Feel free to chime in with your own stories of minor failures that caused total shutdowns in the comments. Video below the break.

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Wherein The Mechanical Keyboard Community Discovers Motorized Linear Potentiometers

Deep in the bowels of the Digikey and Mouser databases, you’ll find the coolest component ever. Motorized linear potentiometers are a rare, exotic, and just plain neat input device most commonly found on gigantic audio mixing boards and other equipment that costs as much as a car. They’re slider potentiometers with a trick up their sleeve: there’s a motor inside that can set the slider to any position.

The mechanical keyboard community has been pushing the boundaries of input devices for the last few years, and it looks like they just discovered motorized linear pots. [Jack] created a motorized sliding keycap for his keyboard. It’s like a scroll wheel, but for a keyboard. It’s beautiful, functional, and awesome.

The hardware for this build is just about what you would expect. A 60 mm motorized linear pot for the side-mount, or 100 mm mounted to the top of the keyboard, is controlled by an Arduino clone and a small motor driver. That’s just the hardware; the real trick here is the software. So far, [Jack] has implemented a plugin system, configuration software, and force feedback. Now, messing with the timeline in any Adobe product is easy and intuitive. This device also has a ‘not quite vibration’ mode for whenever [Jack] gets a notification on his desktop.

Right now, [Jack] is running a group buy for this in a reddit thread, with the cost somewhere between $55 and $75, depending on how many people want one. This is a really awesome product, and we can’t wait for Corsair to come out with a version sporting innumerable RGB LEDs. Until then, we’ll just have to drool over the video [Jack] posted below.

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This Binary Keyboard Is For ASCII Purists

So, you’re a keyboard enthusiast. The ‘board that came from Dell, HP, or whoever made your computer is just not for you. You have an ancient IBM, a decal-free Das Keyboard, or another similarly esoteric text input device. Your typing can be heard three blocks away as the unmistakable clack of bent-spring switches reverberates around you, but you don’t care because you’re in the Zone.

No keyboard can be as high-end as the one you already have, your position in the hierarchy of text entry is assured. But then along comes [Chris Johnston] with his project, and suddenly your desktop looks very cluttered. It’s a binary keypad with only a 0 key, a 1 key, and an OLED display. All input is as a series of binary bytes, so as a hardcore binary typist you’ll need to know your ASCII.

Behind the keys is an Arduino Pro Micro acting in USB HID mode, and running the code you can download from the GitHub link above. It’s a gloriously pointless input device, but we’re sure you’ll agree it has something of the 00110001 00110011 00110011 00110111 about it.

If you think you may have seen this before on Hackaday then you’re not quite right. We have had a binary keypad in the past, but that one had a return key and thus had three keys. This one’s a 2-key ‘board for binary purists.

[via /r/mechanicalkeyboards/]