Hackaday Links: January 3, 2016

Cx5 is a strange material that’s a favorite of model makers and prop replicators. It’s kind of like a wax, kind of like a clay, and a little bit like a plastic. Now it’s a 3D printer filament. It looks very interesting for sculpted and highly detailed models, something the 3D printing scene hasn’t had yet.

So you want a CNC machine, right? Tormach makes a good one, and here’s what it takes to put a PCNC440 in your garage. This is an incredible amount of work and a great excuse to buy an engine hoist.

[Zemnmez] could find dozens of apps and webpages that would calculate resistor color codes for him automatically. What he couldn’t find is one that would do it in reverse – i.e. type in a resistor value and return the correct color code. He made this.

[aggaz] needed a way to connect multiple MIDI devices to his computer. The MIDI spec provides a neat piece of hardware for just this occasion – the MIDI thru box. The only thing you need to build a single MIDI thru box is an opto-isolator and a buffer. It’s easy enough to build, although the DIN5 jacks used for MIDI devices are pretty expensive nowadays. (FWIW- We get an invalid certificate error when loading this page but you should still be able to load it.)

AliExpress always has some interesting stuff on it, and [Ethan] found something very cool. They’re A8 CPUs found in the latest iPhone. Are they real? Who knows. I bought one, and you’re going to get pictures in another links post in a month or so.

The Game Boy Micro was released by Nintendo in 2005 and quickly became one of the coolest and most desired handheld consoles on the planet. You need only look at the eBay listings for the Micro as evidence of its desirability. [ModPurist] took an old DS Lite and converted it into a Game Boy Micro – same idea, larger package.

Frank Makes A CNC Table

[Frank Howarth] is one of the big guns when it comes to woodworking on YouTube, and now he’s doing something completely unlike his other builds. He’s building a gigantic CNC machine. Yes, we’ve seen dozens of CNC router builds, but this one adds a few nifty features we’ve never seen before.

The plans for [Frank]’s CNC machine call for a 4 foot by 8 foot table, over which a router on a gantry gnaws away at wood. This is the standard size for shop-sized CNC router, but [Frank] is adding in his own twist: he’s building a 12 foot long table, by way of a four foot extension. This one small addition allows [Frank] to put tenons in tree trunks, engravings on the side of furniture, or just to make one part of a very large piece flat.

Right now, the build is just about the base, constructed out of 2″ square steel tube. While the welding is by all accounts an amateur job, everything is square, straight, and true. Now, with a metal base scooting around on hockey puck feet, [Frank] is ready to start on the robotic part of the build, something we’re all interested to see.

It’s going to be really big, but still not the biggest.

Development Tools of the Prop-Making World

We’ve seen them before. The pixel-perfect Portal 2 replica, the Iron Man Arc Reactor, the Jedi Lightsaber. With the rise of shared knowledge via the internet, we can finally take a peek into a world hidden behind garage doors, basements, and commandeered coffee tables strewn with nuts, bolts, and other scraps. That world is prop-making. As fab equipment like 3D printers and laser cutters start to spill into the hands of more people, fellow DIY enthusiasts have developed effective workflows and corresponding software tools to lighten their loads. I figured I’d take a brief look at a few software tools that can open the possibilities for folks at home to don the respirator and goggles and start churning out props.

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Breaking Out A Game Boy Link Cable

[Samuel] is working on one of the most important electronics projects of our generation. He’s building a device for the Game Boy that will allow Pokemon trades between generation II and III. Yes, This means bringing your Charmander from Pokemon Red to your team in Pokemon Ruby, Sapphire, or Emerald. and finally completing the National Dex you’ve been working on for 20 years. Before he gets to designing this system, he first needs to listen in on the Game Boy Link Cable, and that means creating a breakout board.

The Game Boy Link Cable – sometimes inaccurately referred to as the Zelda cable – is a special proprietary connector. The design is well documented, but unlike the Wii Nunchuck controller, there’s no readily available breakout board available for this piece of obsolete technology.

Together with a his friend [David], [Samuel] loaded up a copy of Eagle and designed a board that will fit on a small piece of copper clad FR4. This design was then sent over to a small CNC mill, The traces were machined away, and a sextet of pins were soldered into the holes.

With a breakout board for the Game Boy Link Cable, [Samuel] now has a great platform for peering into the strange and magical world of Pokemon. He’ll be using a Teensy microcontroller for his trading device, and with several similar projects already completed by others around the Internet, the potential for a Gen II to Gen III Pokemon trader is palpable.

Superbike gets Bootstrapped Instrument Refit

[Josh] got rid of the standard, factory gauges on his GSXR Super-bike and installed a custom built instrument panel which displays some additional parameters which the regular instrumentation cluster did not. He was working on converting his bike in to a Streetfighter – a stripped down, aggressive, mean machine. The staid looking gauges had to go, besides several other mods to give his bike the right look.

GSXR_03Luckily, he had the right skills and tools available to make sure this DIY hack lives up to the Streetfighter cred of his bike. The important parameter for him was to log the Air / Fuel mixture ratio so he could work on the carburation. Along the way, he seems to have gone a bit overboard with this build, but the end result is quite nice. The build centers around a Planar 160×80 EL graphic display lying in his parts bin. The display didn’t have a controller, so he used the Epson S1D13700 graphic controller to interface it with the microcontroller. An Atmel ATmega128L runs the system, and [Josh] wrote all of his code in “C”.

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Hackaday Prize Semifinalist: CNC Becomes Pick and Place

In the 80s and 90s, building a professional quality PCB was an expensive proposition. Even if you could afford a few panels of your latest board, putting components on it was another expensive process. Now, we have cheap PCBs, toaster-based solder ovens, and everything else to make cheap finished boards except for pick and place machines. ProtoVoltaics’ semifinalist entry for the Hackaday Prize is the answer to this problem. They’re taking a cheap, off-the-shelf CNC machine and turning it into a pick and place machine that would be a welcome addition to any hackerspace or well-equipped garage workshop.

Instead of building their own Cartesian robot, ProtoVoltaics is building their pick and place around an X-Carve, a CNC router that can be built for about $1000 USD. To this platform, ProtoVoltaics is adding all the mechanics and intelligence to turn a few webcams and a CNC machine into a proper pick and place machine.

Among the additions to the X-Carve is a new tool head that is able to suck parts out of a reel and spit them down on a blob of solder paste. The webcams are monitored by software which includes CUDA-accelerated computer vision.

Of course a pick and place machine isn’t that useful without feeders, and for that, ProtoVoltaics built their own open source feeders. Put all of these elements together, and you have a machine that’s capable of placing up to 1000 components per hour; more than enough for any small-scale production, and enough for some fairly large runs of real products.

You can check out some of the videos for the project below.

The 2015 Hackaday Prize is sponsored by:

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When you think of a CNC controller you probably think of a PC with a parallel port or some microcontroller-based solution like a Smoothie Board. [Mhouse1] has a different idea: use FPGAs as CNC controllers.

FPGAs inherently handle things in parallel, so processing G code, computing curves and accelerations, and driving multiple stepper motors at one time would not be an issue at all for an FPGA. Most computer-based designs will have slight delays when trying to drive everything at once and this introduces some mechanical jitter. Even worse jitter occurs when you have an old PC trying to run everything when some other task takes over the CPU.

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