Powering vehicles with aluminum

Pop a few aluminum bits into this little RC racer and you’ll have power for around forty minutes. This concept, which has been patented, is the result of a college research project. It uses a chemical reaction between aqueous Sodium Hydroxide and aluminum. The result of that reaction is hydrogen, which is gathered and directed to a fuel cell that drives the car.

Novel? Yes. Interesting? Absolutely. But you should be raising an eyebrow at the dubious choice of fuel that is aluminum.

If you don’t know what we’re talking about let us paint you a picture. Aluminum is a metal that is refined from bauxite ore. It takes an immense amount of electricity to smelt the metal. This is usually justified because aluminum is one of the most recyclable substances on earth, capable of being melted down and reformed countless times. But dissolving it in drain cleaner breaks it down and then it’s gone. So what we have here simply must be the least efficient disposable battery so far developed. It’d probably use less resources to grow and harvest lemons as a power source.

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Making boxes from soda cans

This shiny little box was made from a soda can. You don’t need much to pull this off; an aluminum can, sand paper, scissors, a ballpoint pen, a straight edge, and some time. The embossing is done with the tip of the pen, but there’s a bit of a trick to it. The designs are first pressed into the metal from the underside of the aluminum. It is then flipped over and the outlines are traced, with one last tracing of the shape from the underside once that is completed. We think you’ll agree that this results in an impressive relief of the design.

This would make a nice project for that wedding ring you’ve been carrying around sans-case. Or perhaps this is just what you needed as an enclosure for your next project. You’ll find an instructional video after the break.

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Jeri makes flexible EL displays

A failed chemistry experiment led [Jeri Ellsworth] to discover a flexible substrate for electroluminescent displays. We’re familiar with EL displays on the back of a glass panel like you would find in an audio receiver, but after making a mesh from aluminum foil [Jeri] looked at using the porous metal to host phosphors. She starts by cleaning foil and using a vinyl sticker to resist etching portions of the aluminum. It then goes into a bath of boric acid, electrified with the foil as the anode. As the foil etches she tests the progress by shining a laser through the foil. After this the phosphors are applied to the back surface of the foil, covered in a dielectric, and topped off with a conductive ink that will carry the AC necessary to excite the phosphors. This is layering materials in reverse compared to her EL PCB experiments. See [Jeri] explain this herself in the clip after the break.

You can see above that this produces a pretty well-defined display area. It reminds us of that color changing paint display. We think it would be worth a try to build a few 7-segment displays using this method.

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Machined steadicam, steadier than the rest

No, the picture above is not a store made steadicam. Rather, a CNC machined one by [Matt]. Interestingly, unlike most steadicams we’ve seen before the gimbal is not the main focus of the design though an aluminum machined gimbal would make us drool. The central idea is allowing for X and Y axis adjustment to get oddly weighted bulky camera’s exact center of gravity. [Matt's] steadicam is also designed to handle more weight than commercial versions, and (if you already have a CNC) to be much cheaper. There’s no video, but from the skill of craftsmanship we can safely assume it’s as good and level as some of the best.

Use a big magnet to set the time

This bulky package is a Nixie tube wristwatch. We still like [Woz’s] watch better but this one has a few nice tricks of its own. Notably, there aren’t any buttons to set the time. Instead, a large magnet is used to actuate a magnetic switch inside the body. Speaking of enclosures, the case is aluminum and the face plate is polycarbonate but looks like it’s been vacuum formed. Check out the clip after the break.

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Indestructible TI-89

Sometimes, expensive calculators hit the floor. It’s happened to almost anyone with a graphing calculator from TI or HP. Sadly, they don’t always bounce. After this happened to [Howard C.], an Industrial Engineering student from U. of Iowa, he decided to spend $50 on milling his own replacement case out of aluminum rather than trashing the device over a broken battery compartment. [Howard] chose to send us the story rather than write his own blog, so we’ve included all the great pictures he sent us after the break.

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All metal hot end for Makerbot

Imagine if you will for a moment, you’re printing along on your Makerbot clone and all of a sudden your PTFE hot end melts, what are you going to do now? One solution is to mill your own all metal end from a bolt with some careful drilling. Or you could follow [Peter Jansen] who has made his own all metal hot end using the existing extruder. All that’s required is some aluminum sheet and cutting down the nozzle and hat (and fans to help, but technicalities), and you’re in business with no more melted PTFE hot end.