Ester, The Open Source SLS Printer

November 19, 2014 by Brian Benchoff 24 Comments

Filament printers are here to stay, and in the past year there have been a number of SLA and DLP resin printers that can create objects at mind-boggling high resolutions. Both of these technologies have their place, but printing really complex objects without also printing supports is out of the question.

[Brandon] has been working to create an open source printer using a different technology, selective laser sintering. That’s a laser melting tiny particles of stuff to create an object. This printer can work with any material that can be turned into a powder and melted by a laser, and also has the neat bonus of printing without any supports.

[Brandon]’s printer, Ester, uses small meltable polyester dust as both a print material and support structure. The object to be printed is created by shining a laser over a bed filled with polyester, drawing one layer, and putting another small layer of material over the previous layer.

The machine is using a diode laser, with a few experiments with a 1 Watt diode providing some very nice parts. The mechanics of the machine were built at [Brandon]’s local TechShop, and already he has an IndieGoGo for future development and a $3000 development kit. That’s a bit expensive as far as project printers go, but SLS is an expensive technology to get right; ‘pro’ SLS printers are in the hundreds of thousands of dollars.

A Raspberry Pi In A Game Boy Advance SP

November 19, 2014 by Brian Benchoff 21 Comments

It’s not the biggest use of a Raspberry Pi, but running emulators for old game systems is by far the most visible use of the Pi. In fact, putting Pis inside old game systems has led to a resurgence of case modding not seen since the heyday of the Mini-ITX craze of the early ‘aughts.

You’d think every possible Pi casemod had been done by now, but [frostedfires] is still raising the bar with a Pi casemod that stuffs a clone of everyone’s favorite credit card sized computer into a Game Boy Advance SP.

[frostedfires] isn’t using a real Raspi from The Foundataion. Instead, he found the Odroid W, a raspi compatible board that’s about half the size of a model B. It still has everything needed to complete the build – analog video out, a reasonable Linux system, and enough processing power to run Quake III. Right now, [frostedfires] has the screen working – that was taken from a car backup camera. Other than that, the only portion of the build left to go is a few buttons.

This is officially the smallest derivative casemod we’ve ever seen. the previous record holder was the still tiny Game Boy Pocket build from last summer. That build required heavy modifications to the Model B board, though, so if you’re aiming for a smaller build, the Odroid is the way to go.

Thanks to the Bacman forums for yet another great build.

Laser-cut Album Released

November 19, 2014 by Elliot Williams 15 Comments

In some alternate universe, where laser cutters and phonographs are more common than MP3 players, it makes a ton of sense to release laser-cutter files for your band’s new album (Translated). In this universe, it’s wacky and awesome.

The new EP from ASIC, alias [Patric] from Fablab Zürich, is out as PDF before it’s out in other forms of digital download, and the trailer video (embedded below the break) looks fantastic.

The release draws on this Instructable by Amanda Ghassaei to turn the music into PDFs suitable for feeding into a laser cutter, and we think it’s classy that she gets a shout-out on the label’s release page. Everything else about the album will be released under a Creative Commons license to boot.

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Push Button, Receive Bacon.

November 19, 2014 by Adam Fabio 28 Comments

Members of the Rabbit Hole hackerspace spent the last weekend competing in The Deconstruction, a 48 hour hackathon competition. The hackerspace’s theme was “Light it up!”, so members created some awesome projects involving light. The star of the show was their bacon cooking machine. The Rabbit hole made the “Push Button. Receive Bacon” meme real.

A broken laser printer was gutted for its drive train and fuser assembly. Laser printer fusers are essentially hot rollers. The rollers melt toner and fuse it with paper as it passes through the printer. The heat in this case comes from a lamp inside the roller. That lamp also puts out plenty of light, which fit perfectly with the team’s theme.

The Rabbit Hole members wasn’t done though, they also built a pocket-sized infinity mirror from an empty Altoids tin. The bottom of the tin was cut out, and a mirror glued in. A filter from a broken projector made a perfect half silver mirror, and some LEDs completed the project.

The members also built a fandom art piece, consisting of 25 fans connected together in a skull shape. The eye and nose fans were lighted. When the fans were plugged in, they kicked for a few seconds before spinning up. Once they did spin though – there was a mighty wind in the Rabbit Hole.

Click past the break for The Rabbit Hole’s Deconstruction video!

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Interview With A Printer

November 19, 2014 by Brian Benchoff 21 Comments

The Hackaday European tour continues, this time in Prague with Josef Průša (Google translate), core developer in the RepRap project, feature at all the Maker Faires and cons, and creator of his namesake, the Prusa Mendel and i3 printers.

[Prusa]’s involvement with the RepRap project started with a RepRap Mendel, the second iteration of RepRap hardware, but the first popular and easy to build version. [Jo] found the Mendel rather difficult to build, so he loaded OpenSCAD and started to design his own version of the hardware. This version became the de facto standard RepRap for a few years, with many inspired by and derivative printers making their way to hackerspaces and workshops around the world.

The first Prusa printer, derived from the RepRap Mendel.

A few years ago, [Prusa] was one of the first to make a complete break with the traditional ‘threaded rod and nut’ construction of RepRaps with the introduction of the Prusa i3. This was the first model that had a metal plate as the frame, another feature that would be seen in dozens of other models. It’s not something that was without controversy, either; using a metal plate for the frame doesn’t allow for as much self-replication, something that’s a core value of the RepRap project. That didn’t matter to the community; the Prusa i3 or a similar design is the third most popular printer on 3Dhubs.

The first Prusa printer showing off its Makerbot heritage

What’s the future of the Prusa name? There is an i4 in the works, and I’m pretty sure that’s all I can tell you. Someone already bought the Prusai4 domain, so there may be a name change.

In the interview below, [Prusa] goes over his involvement with the RepRap project, his business, what he considers to be the latest advances in 3D printing for the past year, what the worst things about the 3D printing scene is (it’s Kickstarter), the state of the RepRap project, and thoughts on SLS, DLP, and SLA printing technologies. Video below.

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Programmable Lithium Charger Shield For Arduino

November 19, 2014 by Marsh 12 Comments

Surely you need yet another way to charge your lithium batteries—perhaps you can sate your desperation with this programmable multi (or single) cell lithium charger shield for the Arduino?! Okay, so you’re not hurting for another method of juicing up your batteries. If you’re a regular around these parts of the interwebs, you’ll recall the lithium charging guide and that rather incredible, near-encyclopedic rundown of both batteries and chargers, which likely kept your charging needs under control.

That said, this shield by Electro-Labs might be the perfect transition for the die-hard-‘duino fanatic looking to migrate to tougher projects. The build features an LCD and four-button interface to fiddle with settings, and is based around an LT1510 constant current/constant voltage charger IC. You can find the schematic, bill of materials, code, and PCB design on the Electro-Labs webpage, as well as a brief rundown explaining how the circuit works. Still want to add on the design? Throw in one of these Li-ion holders for quick battery swapping action.

[via Embedded Lab]

RTL SDR As A Spectrum Analyzer

November 19, 2014 by Brian Benchoff 24 Comments

RTL-SDR, the USB TV tuner turned software-defined radio is an amazing device, capable of listening to nearly anything from 25MHz to 1750MHz, fits in your pocket, and costs about $20. Even more astonishing is that it’s also a kinda-okay spectrum analyzer. [Kerry D. Wong] tested out one of these USB TV tuner, and the results are exactly what you would expect: it lacks a little precision, and sampling bandwidth is only a tiny bit terrible, but it does work.

A stock USB TV tuner doesn’t come with a connector that would normally be used for spectrum analysis. A BNC connector can be easily attached, as can a terminator to match the 75Ω impedance of the SDR. This isn’t really necessary; the frequencies being measured are low enough that you can get away without one.

As far as software goes, [Kerry] first pulled out the usual suspects of the SDR world; rtlsdr-scanner distorted the measured spectrum, as did a lot of other SDR receivers. Gqrx SDR was the first one that worked well, but the king of this repurposing of USB TV tuners was OSMOCOM. There’s a huge number of tools for spectrum analysis right out of the box with this package.

How did the RTL SDR fare as a spectrum analyzer? Feeding some stuff in from a signal generator, [Kerry] discovered the LO in the RTL SDR was off by a hair. Also, OSMOCOM only measures amplitude in dB, not the dBm found in every other spectrum analyzer ever made. By measuring a 0 dBm signal whatever value displayed can be shifted up or down.

So, does it work? Yes, it does. If, for some reason, you need a spectrum analyzer now, can you use this? Yep. Pretty cool.