Mechanical Clock Designed For A CNC Router Gets New Life Using A 3D Printer

June 10, 2014 by James Hobson 4 Comments

[Madis Kaasik] designed a clock a while back using Solid Edge (3D CAD) — but never got a chance to build it — until he became an exchange student at a university in Norway with access to a big industrial 3D printer!

He had originally intended for it to be cut out using a CNC router or with a laser cutter, but when discovered he could use the university’s 3D printer he decided to give it a shot — it’s actually the very first thing he’s ever printed! The designs had to be modified a little bit for 3D printing, but now that it’s done he’s also uploaded them to Thingiverse for anyone to use.

It took quite a bit of fine tuning with the pendulum, weights, and gears to get it ticking properly, but what [Madis] enjoyed most about this project was the realization of just how vast the possibilities of 3D printing are — he’s excited to begin his next big 3D printing endeavor!

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Judge Spotlight: Jack Ganssle

June 10, 2014 by Mike Szczys 11 Comments

This week we’re getting to know The Hackaday Prize Judge [Jack Ganssle] a little better. His depth of experience with embedded systems is formidable, and recently I was very interested to learn about his mission to improve the quality of the product in the embedded code universe. We’ll get to that in a little bit, but I wanted to start off with [Jack’s] answer to my final question.

Is there anything else you’d like our audience to know about you?

My entry into this field was when the first 8 bit processor (the 8008) came out, and still find it endlessly fascinating. I write a lot about embedded topics, and give talks and seminars, on all of the continents except Antarctica (so far!). We live in heavily-wooded Finksburg, MD, which is just stunning this time of year, and, since my office is in the house, the commute is pretty tolerable. Other passions include sailing; I wrote an on-line book (www.ganssle.com/jack) about racing alone across the Atlantic. Great trip, other than losing the boat.

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DIY Embroidery Machine Sews Your Name In Your Undies

June 10, 2014 by Rich Bremer 32 Comments

DIY Embroidery Machine

If you were in the market for a sewing machine with embroidery capabilities, you’d either be spending a bunch of money or settling for a lower-cost machine that can only do a handful of pre-programmed designs. A DIYer by the name of [SausagePaws] came up with a 3rd option, he would build one himself. He was also highly motivated, [Mrs SausagePaws] wanted one!

An off the shelf embroidery machine is similar to a standard sewing machine except the movement of the fabric is done automatically rather than by hand. Not only does the work move, but it has to move in time with the needle traveling up and down. [SausagePaws] took a no-nonsense approach and decided the simplest way to go about the task was to mount an embroidery hoop to the end of an XY drive system.

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Measuring Car Engine RPM Via The Cigarette Lighter

June 10, 2014 by Mathieu Stephan 57 Comments

Sometimes we forget how many things we can do with a simple oscilloscope. In this video [Ben] uses one that Tektronix lent him to measure his DeLorean engine RPM. By checking the car main ~12V voltage one may notice that the voltage spikes occurring are directly related to the engine speed, as they are created by the inductive kicks from the ignition coils. Obviously the multiplication you have to do to get the RPMs from the number of spikes per second depends on your engine configuration (flat 4, v6…).

The method that [Ben] used was to search for high amplitude spikes on the (AC coupled) car 12V Fast Fourier Transform (FFT) to get a reliable measurement given the many electrical noise sources present in his car. At the end of his video, he however mentioned that it could still be possible to get a good measurement with a simple voltage comparator and a high enough voltage reference.

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Hacking A MagSafe Connector For Your IPhone

June 9, 2014 by James Hobson 23 Comments

maglock

The MagSafe power connector for Apple MacBooks is probably one of the handiest features they developed — we’re not too sure why it hasn’t been integrated onto iPhones yet. [Tony Hoang] isn’t sure either, but that didn’t stop him making his very own!

Due to the size of the MagSafe adapter, it’s simply not possible to integrate it directly into an iPhone, so [Tony] took his trusty Otter-box case and modified it instead. He’s using a Qi wireless charging receiver on the inside of the case, because it has a very slim ribbon cable to the USB. Modifying that he was able to solder on the MagSafe adapter directly to the ribbon cable. In order for it to fit nicely through the case, he 3D printed an adapter bracket for it to stay nice and secure.

From there it was just a matter of soldering the MagSafe power cable onto a 5V USB power brick, and boom-bada-bing, he’s got a MagSafe compatible iPhone. Previously he’s done this mod to a Samsung Note II, and plenty of other people have added it to laptops and ultrabooks!

A Head Unit Docking Station

June 9, 2014 by Brian Benchoff 22 Comments

dock

[Ivan] had a simple idea: being able to control his Android device from the small keypad on his car’s steering column. This would allow him to cycle through apps, navigation, and audio tracks while never taking his hands off the wheel. Feature creep then set in and [Ivan] asked himself how he could charge his phone through the same interface. What he ended up with is a head unit that’s also a dock.

While [Ivan]’s steering wheel doesn’t have the nice integrated remote control buttons found in newer cars, he does have a Blaupunkt remote, a small, clip-on controller that has a an IR transmitter on it. The IR receiver was connected to a PIC microcontroller, sending commands to the phone for up, down, left, right, menu, and home. Audio output from the phone is handled by a small USB sound card connected to a USB hub, sending the audio signals directly into the head unit’s amplifier.

Having the phone charge while it’s still in USB host mode is the crucial part of this build; not being able to charge on a long car ride would quickly drain the battery and make a car dock kind of pointless. To accomplish this, [Ivan] simulated a Galaxy S4 dock with a few resistors in the USB port, allowing the phone to control the USB sound card, listen to the emulated keyboard and mouse, and charge at the same time.

It’s not a pretty build, but it is extraordinarily useful. In the videos you can see that [Ivan] pretty much pulled this build together from stuff he had sitting around – a great reuse of junk, and a great addition to his car at the same time.

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THP Entry: An Affordable Metal 3D Printer

June 9, 2014 by Brian Benchoff 41 Comments

metal For years now, people have been trying to develop an affordable, RepRap-derived 3D printer that will create objects in metal. There has been a lot of work with crazy devices like high-powered lasers, and electron beams, but so far no one has yet developed a machine that can print metal objects easily, cheaply and safely. For The Hackaday Prize, [Sagar] is taking a different tack for his metal 3D printer: he’s extruding low temperature alloys just like a normal 3D printer would extrude plastic.

[Sagar]’s printer is pretty much a carbon copy of one of the many ‘plastic-only’ 3D printers out there, the only change being in the extruder and hot end. As a material, he’s using an alloy of 95.8% tin, 4% copper, and 0.2% silver in a 3mm diameter spool. This alloy melts at 235° C, about the same temperature as the ABS plastic these printers normally use.

The only real problems with this build are the extruder and nozzle. [Sagar] is milling his own nozzle and hot end out of stainless steel; a challenging bit of machining, but still within the realm of a hobbyist. He has some doubts about the RepRap derived plastic geared extruder being able to handle metal, so he’s also looking at designing a new version and milling that out of stainless as well.

It’s an awesome project, and we hope we’ll be seeing some updates to the project shortly. While a 3D printer that produces objects out of a low temperature alloy won’t be building rocket engines any time soon, it could be a great way to fabricate some reasonably high-strength parts at home.

The project featured in this post is an entry in The Hackaday Prize. Build something awesome and win a trip to space or hundreds of other prizes.