Two clear acrylic tubes are shown in the foreground. Swirls of sawdust are visible on the inside of the tubes, and the tubes are held in place by grey plastic connectors. Below the tubes, there are two clear plastic tubs containing sawdust.

Optimizing Dust Separation For Extreme Efficiency

June 26, 2025 by Aaron Beckendorf 15 Comments

[Ruud], the creator of [Capturing Dust], started his latest video with what most of us would consider a solved problem: the dust collection system for his shop already had a three-stage centrifugal dust separator with more than 99.7% efficiency. This wasn’t quite as efficient as it could be, though, so [Ruud]’s latest upgrade shrinks the size of the third stage while increasing efficiency to within a rounding error of 99.9%.

The old separation system had two stages to remove large and medium particles, and a third stage to remove fine particles. The last stage was made out of 100 mm acrylic tubing and 3D-printed parts, but [Ruud] planned to try replacing it with two parallel centrifugal separators made out of 70 mm tubing. Before he could do that, however, he redesigned the filter module to make it easier to weigh, allowing him to determine how much sawdust made it through the extractors. He also attached a U-tube manometer (a somewhat confusing name to hear on YouTube) to measure pressure loss across the extractor.

The new third stage used impellers to induce rotational airflow, then directed it against the circular walls around an air outlet. The first design used a low-profile collection bin, but this wasn’t keeping the dust out of the air stream well enough, so [Ruud] switched to using plastic jars. Initially, this didn’t perform as well as the old system, but a few airflow adjustments brought the efficiency up to 99.879%. In [Ruud]’s case, this meant that of 1.3 kilograms of fine sawdust, only 1.5 grams of dust made it through the separator to the filter, which is certainly impressive in our opinion. The design for this upgraded separator is available on GitHub.

[Ruud] based his design off of another 3D-printed dust separator, but adapted it to European fittings. Of course, the dust extractor is only one part of the problem; you’ll still need a dust routing system.

Thanks to [Keith Olson] for the tip!

Linear Solar Chargers For Lithium Capacitors

June 26, 2025 by Bryan Cockfield 24 Comments

For as versatile and inexpensive as switch-mode power supplies are at all kinds of different tasks, they’re not always the ideal choice for every DC-DC circuit. Although they can do almost any job in this arena, they tend to have high parts counts, higher complexity, and higher cost than some alternatives. [Jasper] set out to test some alternative linear chargers called low dropout regulators (LDOs) for small-scale charging of lithium ion capacitors against those more traditional switch-mode options.

The application here is specifically very small solar cells in outdoor applications, which are charging lithium ion capacitors instead of batteries. These capacitors have a number of benefits over batteries including a higher number of discharge-recharge cycles and a greater tolerance of temperature extremes, so they can be better off in outdoor installations like these. [Jasper]’s findings with using these generally hold that it’s a better value to install a slightly larger solar cell and use the LDO regulator rather than using a smaller cell and a more expensive switch-mode regulator. The key, though, is to size the LDO so that the voltage of the input is very close to the voltage of the output, which will minimize losses.

With unlimited time or money, good design can become less of an issue. In this case, however, saving a few percentage points in efficiency may not be worth the added cost and complexity of a slightly more efficient circuit, especially if the application will be scaled up for mass production. If switched mode really is required for some specific application, though, be sure to design one that’s not terribly noisy.

Rust Drives A Linux USB Device

June 26, 2025 by Al Williams 13 Comments

In theory, writing a Linux device driver shouldn’t be that hard, but it is harder than it looks. However, using libusb, you can easily deal with USB devices from user space, which, for many purposes, is fine. [Crescentrose] didn’t know anything about writing user-space USB drivers until they wrote one and documented it for us. Oh, the code is in Rust, for which there aren’t as many examples.

The device in question was a USB hub with some extra lights and gadgets. So the real issue, it seems to us, wasn’t the code, but figuring out the protocol and the USB stack. The post covers that, too, explaining configurations, interfaces, and endpoints.

There are other ancillary topics, too, like setting up udev. This lets you load things when a USB device (or something else) plugs in.

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Announcing The 2025 Hackaday One Hertz Challenge

June 26, 2025 by Elliot Williams 48 Comments

It’s about time! Or maybe it’s about time’s reciprocal: frequency. Whichever way you see it, Hackaday is pleased to announce, just this very second, the 2025 One Hertz Challenge over on Hackaday.io. If you’ve got a device that does something once per second, we’ve got the contest for you. And don’t delay, because the top three winners will each receive a $150 gift certificate from this contest’s sponsor: DigiKey.

What will you do once per second? And how will you do it? Therein lies the contest! We brainstormed up a few honorable mention categories to get your creative juices flowing.

Timelords: How precisely can you get that heartbeat? This category is for those who prefer to see a lot of zeroes after the decimal point.
Ridiculous: This category is for the least likely thing to do once per second. Accuracy is great, but absurdity is king here. Have Rube Goldberg dreams? Now you get to live them out.
Clockwork: It’s hard to mention time without thinking of timepieces. This category is for the clockmakers among you. If your clock ticks at a rate of one hertz, and you’re willing to show us the mechanism, you’re in.
Could Have Used a 555: We knew you were going to say it anyway, so we made it an honorable mention category. If your One Hertz project gets its timing from the venerable triple-five, it belongs here.

We love contests with silly constraints, because you all tend to rise to the challenge. At the same time, the door is wide open to your creativity. To enter, all you have to do is document your project over on Hackaday.io and pull down the “Contests” tab to One Hertz to enter. New projects are awesome, but if you’ve got an oldie-but-goodie, you can enter it as well. (Heck, maybe use this contest as your inspiration to spruce it up a bit?)

Time waits for no one, and you have until August 19th at 9:00 AM Pacific time to get your entry in. We can’t wait to see what you come up with.

How To Make A Beautiful Floral Keycap Using Resin

June 26, 2025 by John Elliot V 8 Comments

Here’s a fun build. Over on their YouTube channel our hacker [Atasoy] shows us how to make a custom floral keyboard keycap using resin.

We begin by using an existing keycap as a pattern to make a mold. We plug the keycap with all-purpose adhesive paste so that we can attach it to a small sheet of Plexiglas, which ensures the floor of our mold is flat. Then a side frame is fashioned from 100 micron thick acetate which is held together by sticky tape. Hot glue is used to secure the acetate side frame to the Plexiglas floor, keeping the keycap centered. RTV2 molding silicone is used to make the keycap mold. After 24 hours the silicone mold is ready.

Then we go through a similar process to make the mold for the back of the keycap. Modeling clay is pushed into the back of the keycap. Then silicone is carefully pushed into the keycap, and 24 hours later the back silicone mold is also ready.

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Field Guide To The North American Weigh Station

June 26, 2025 by Dan Maloney 38 Comments

A lot of people complain that driving across the United States is boring. Having done the coast-to-coast trip seven times now, I can’t agree. Sure, the stretches through the Corn Belt get a little monotonous, but for someone like me who wants to know how everything works, even endless agriculture is fascinating; I love me some center-pivot irrigation.

One thing that has always attracted my attention while on these long road trips is the weigh stations that pop up along the way, particularly when you transition from one state to another. Maybe it’s just getting a chance to look at something other than wheat, but weigh stations are interesting in their own right because of everything that’s going on in these massive roadside plazas. Gone are the days of a simple pull-off with a mechanical scale that was closed far more often than it was open. Today’s weigh stations are critical infrastructure installations that are bristling with sensors to provide a multi-modal insight into the state of the trucks — and drivers — plying our increasingly crowded highways.

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PLA With PETG Core Filament Put To The Test

June 26, 2025 by Maya Posch 27 Comments

The Stronghero 3D hybrid PLA PETG filament, with visible PETG core. (Credit: My Tech Fun, YouTube)

Sometimes you see an FDM filament pop up that makes you do a triple-take because it doesn’t seem to make a lot of sense. This is the case with a hybrid PLA/PETG filament by Stronghero 3D that features a PETG core. This filament also intrigued [Dr. Igor Gaspar] who imported a spool from the US to have a poke at it to see why you’d want to combine these two filament materials.

According to the manufacturer, the PLA outside makes up 60% of the filament, with the rest being the PETG core. The PLA is supposed to shield the PETG from moisture, while adding more strength and weather resistance to the PLA after printing. Another interesting aspect is the multi-color look that this creates, and which [Igor]’s prints totally show. Finding the right temperatures for the bed and extruder was a challenge and took multiple tries with the Bambu Lab P1P including bed adhesion troubles.

As for the actual properties of this filament, the layer adhesion test showed it to be significantly worse than plain PLA or PETG when printed at extruder temperatures from 225 °C to 245 °C. When the shear stress is put on the material instead of the layer adhesion, the results are much better, while torque resistance is better than plain PETG. This is a pattern that repeats across impact and other tests, with PETG more brittle. Thermal deformation temperature is, unsurprisingly, between both materials, making this filament mostly a curiosity unless its properties work much better for your use case than a non-hybrid filament.

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