Mechanical Bird Actually Flies By Flapping Its Wings

October 12, 2014 by James Hobson 38 Comments

Turns out you don’t have to be a multi-million dollar corporation like Festo to create a remote controlled, flapping bird robot. [Kazuhiko Kakuta] is a medical Doctor of Allergy, and in his free time he likes to build flying mechanical birds with his son.

It has just over a meter wingspan, weighs 193 grams, and it flies by flapping its wings. The majority of its components are 3D printed. If that’s not impressive enough for you as is, consider this. It it has no sensors, no gyroscopes or anything — it’s all manually controlled by [Kazuhiko].

And this isn’t even the only ornithopter he’s done. He’s also created something out of an anime film, Castle in the Sky. He even sells the designs for one of them, to be printed via Shapeways.

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Custom Video Streaming Box

October 12, 2014 by Bryan Cockfield 25 Comments

There are a lot of options out today for streaming video to your Internet-connected devices. Whether it’s Hulu, Netflix, Slingbox, or the late Aereo, there is no shortage of ways to get your TV fix. However, [Jaruzel] wasn’t happy with any of these services and wanted a more custom solution, so he built his own TV-streaming box out of hardware he had lying around.

[Jaruzel] gets TV from a service called SkyTV, but wanted to be able to stream it to his tablet, laptop, and XBMC. While rummaging through his parts bin, he came up with a WinTV tuner card for capturing TV and a Mini-ITX board to process everything and stream it out over his network.

Once the computer was put in a custom enclosure, [Jaruzel] got to work installing Puppy Linux. He wrote a boot script that configures the WinTV card and then starts VLC to handle the streaming service which allows him to view the TV stream over HTTP on the network. This is a great hack that would presumably work for any TV stream you can find, even if it’s just an over-the-air source.

Hackaday Links: October 12, 2014

October 12, 2014 by Brian Benchoff 17 Comments

Remember in the late 90s and early 2000s when everything had blue LEDs in them? Blinding blue LEDs that lit up a dark room like a Christmas tree? Nobel prize. There’s a good /r/askscience thread on why this is so important. The TL;DR is that it’s tough to put a p-type layer on gallium nitride.

Have a Segway and you’re a member of the 501st? Here’s your Halloween costume. It’s a model of the Aratech 74-Z speeder bike, most famously seen careening into the side of trees on the forest moon of Endor.

[Andrew] needed something to do and machined an iPhone 5 out of a block of aluminum. Here’s the video of icon labels being engraved. The machine is a Denford Triac with a six station auto tool changer. He’s running Mach3, and according to him everything – including the correct tooling – cost far too much money.

Another [Andrew] was working the LEGO booth at Maker Faire New York and has finally gotten his LEGO Mindstorms Minecraft Creeper build written up. Yes, it’s probably smarter than your average Minecraft Creeper, and this one also blows up. He also had a physical version of the classic video game from 1979, Lunar Lander. Both are extremely awesome builds, and a great way to attract kids of all ages to a booth.

[Wilfred] was testing a titanium 3D printer at work and was looking for something to print. The skull ‘n wrenches was a suitable candidate, and the results are fantastic. From [Wilfred]: “Just out of the printer the logo looks amazing because it isn’t oxidized yet (inside the printer is an Argon atmosphere) Then the logo moves to an oven to anneal the stress made by the laser. But then it gets brown and ugly. After sandblasting we get a lovely bluish color as you can see in the last picture.”

The folks at Lulzbot/Aleph Objects are experimenting with their yet-to-be-released printer, codenamed ‘Begonia’. They’re 2D printing, strangely enough, and for only using a standard Bic pen, the results look great.

Everyone is going crazy over the ESP8266 UART to WiFi module. There’s another module that came up on Seeed recently, the EMW3162. It’s an ARM Cortex M3 with plenty of Flash, has 802.11 b/g/n, and it’s $8.50 USD. Out of stock, of course.

PCB Toner Transfer Method, Now Without The Transfer

October 12, 2014 by Rich Bremer 47 Comments

A common way to create a custom PCB at home is to do what is called the Toner Transfer Method. In this process, the trace layout of the board is printed out on a piece of special toner transfer paper that allows the ink to come off in the following step. The toner transfer paper is then put print-side-down on a copper clad PCB blank, heated and pressed with an iron. The heat and pressure from the iron transfers the toner from the paper to the copper. The exposed copper then is chemically removed, the previously applied toner protects the copper in the pad and trace areas. The toner is then removed using paint thinner.

That is a long process with many critical steps. [mlerman] wondered why no one was printing the toner directly to the PCB. He has been tinkering with printing directly on PCB blanks for 4 years now. He’s made hundreds of boards over that time and can now make a PCB in under 15 minutes.

The obvious route to take would be to modify a current laser printer to accept the much-thicker-than-paper PCB boards. A few printer models were tried but [mlerman] feels the Lexmark E260 works the best due to the cost, internal mechanical components and an easily modifiable manual feed system. There is also a Local Printer Utility that allows the majority of the printer parameters to be adjusted.

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Ghost Gunner Machines Your AR-15

October 12, 2014 by Adam Fabio 193 Comments

Defense Distributed and founder [Cody Wilson] have released Ghost Gunner. Defense Distributed entered the public eye a couple of years ago with The Liberator, the world’s first 3D printed gun. Since anyone with a 3D printer can print a Liberator, it is effectively untraceable. This raised a lot of questions in the media and public eye.

Ghost Gunner is a variation on the untraceable theme. Essentially, Ghost Gunner is a CNC designed for one purpose: final drilling and milling steps for AR-15 lower receivers. The reason for this has to do with federal gun laws in the United States. According to US law, the lower receiver is the actual firearm, and is regulated. But when does a block of aluminum become a lower receiver? Here, US law states that the metal becomes a regulated receiver when the machining operations are more than 80% complete.

Anyone can legally buy a barrel, trigger, stock, upper receiver, and various other parts to build an AR-15. To complete the weapon, they only need to buy an 80% lower receiver and perform the last 20% of the metal work. This work can be performed with everything from a drill press to a milling machine to hand tools. Ghost Gunner partially automates this process, making it easier and faster to complete lower receivers and build weapons.

Defense Distributed calls Ghost Gunner an open source hardware project, though we were unable to find the files available for download at this time. It appears that the slides are made up of MakerSlide or a similar aluminum extrusion. The steppers appear to be standard Nema 17 size.

Defense Distributed says that they’ve been having a hard time keeping up with the Ghost Gunner pre-orders. At $1300 each though, we think a general purpose mill or small CNC would be a better deal.

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Bench Top Drill Press Converted To Milling Machine, Mounted To Lathe

October 12, 2014 by Rich Bremer 22 Comments

Milling machines are nice to have around for precisely drilling holes or removing unwanted material from a part. However, they can be expensive and may not get a lot of use, two reasons why a mill purchase may not make sense for a home shop. [David] didn’t need a mill, he wanted one and he didn’t want to spend a lot of money. He did have an old bench top drill press and a lathe in his shop and thought it would be a good idea to combine them them into a DIY Milling Machine.

The problem with just throwing a milling bit in a drill press and trying to mill metal is that the drill press spindle ball bearings are not made for radial loading. [David] knew this and replaced the stock ball bearings with angular roller bearings. These new bearings would require an axial preload applied to keep the spindle in place. This was done by machining threads into the spindle’s shaft and adding a nut to secure and preload the new angular roller bearings.

[David] did not have an XY Table to donate to the project so he decided to mount the drill press to his lathe and use the lathe axes to move the work piece around underneath the mill. Thick plate steel was welded together to form a hefty bracket that bolted to both the lathe bed and drill press column. And yes, the lathe is still functional and the changeover process is simple. To go from Mill to Lathe; the work piece is removed from the lathe’s cross slide and replaced with the lathe tool holder. That’s it!

Overall, [David] is happy with his conversion. He doesn’t expect his project to be as precise or rigid as a proper milling machine but says he has no problem cutting 1mm deep passes in steel when using a 6mm diameter mill bit.

A Simple Floppy Music Controller

October 12, 2014 by Ethan Zonca 12 Comments

While playing music with floppy drives has been done many times over, making any device with a stepper motor play music still appeals to the hacker in all of us. [Tyler] designed an Arduino shield and a library which lets you get up and running in no time. [Tyler]’s shield includes pin headers to connect 4 floppy drives, which plug directly into the shield. The drives don’t need any modification before being used.

While you could simply wire a few floppy drives up to an Arduino with some jumpers, this breakout shield makes connecting your drives trivial. In addition to designing the shield, [Tyler] released an Arduino library to make things even easier. The library lets you simply set the frequency you want each drive to play, which saves a bit of legwork.

The floppy-controlling Arduino library is available on GitHub and a video of the controller is included after the break.

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