From Broken Drill Bit To Knife: Backyard Forging Basics

May 23, 2015 by James Hobson 21 Comments

One of our tipsters sent in a great video showing how to make knives out of old broken drill bits. It comes from [The Art of Weapons] YouTube channel which is run by a 15 year old from the UK. He’s applying old techniques to modern technology and it’s awesome to see someone young with these skills.

The beauty of this hack is aside from the tools you’ll need, it’s practically free to do. Worn out drill bit or other steel tool? No problem – heat it up and make something new. At the heart of this build is making your own forge. There’s lot of options, from using firebricks, to making a soup can forge like he did. From there, it’s really just a matter of annealing the steel (heating it up to red hot, and letting it cool down slowly in sand), and then heating it up again and forming it with a hammer and anvil.

But he doesn’t stop there: he also shows us his method of making handles for knives out of hardwood — its a pretty cool process and the finished knives are beautiful. The video below is a bit long, but well worth the watch if you’re interested in trying your own hand at forging.

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Hackaday Fail: A $3000 Prototype That Doesn’t Work

May 23, 2015 by Brian Benchoff 113 Comments

[Dan Royer] is hard at work building his own personal robot army. Robots mean motors, and motors mean gearboxes. In [Dan]’s case, gearboxes mean $3000 wasted on a prototype that doesn’t work. Why doesn’t it work? He doesn’t know, and we don’t either.

[Dan] would like to use small but fast DC motors for his robots coupled to a gearbox to step down the speed and increase the torque. The most common way of doing this is with a planetary gear set, but there’s a problem with the design of planetary gears – there is inherent backlash and play between the gears. This makes programming challenging, and the robot imprecise.

A much better way to gear down a small DC motor is a hypocycloid gear. If you’ve ever seen the inside of a Wankel engine, this sort of gearing will look very familiar: a single gear is placed slightly off-axis inside a ring gear. On paper, it works. In reality, not so much.

[Dan] spent $3000 on a prototype hypocycloid gearbox that doesn’t turn without binding or jamming. The gear was made with incredible tolerances and top quality machining, but [Dan] has a very expensive paper weight sitting on his desk right now.

If anyone out there has ever designed or machined a hypocycloid gearbox that works, your input is needed. The brightest minds [Dan] met at the Bring A Hack event at Maker Faire last weekend could only come up with. ‘add more lasers’, but we know there’s a genius machinist out there that knows exactly how to make this work.

Hackaday Fail is a column which runs every now and again. Help keep the fun rolling by writing about your past failures and sending us a link to the story — or sending in links to fail write ups you find in your Internet travels.

Hackaday Prize Entry: Biopotential Signal Library

May 22, 2015 by Brian Benchoff 11 Comments

With prosthetics, EEG, and all the other builds focused on the body and medicine for this year’s Hackaday Prize, it might be a good idea to take a look at what it takes to measure the tiny electrical signals that come from the human body. Measuring brain waves or heartbeats indoors is hard; AC power frequencies easily couple to the high impedance inputs for these measurements, and the signals themselves are very, very weak. For his entry to The Hackaday Prize, [Paul Stoffregen] is building the tools to make EEG, ECG, and EMG measurements easy with cheap tools.

If the name [Stoffregen] sounds familiar, it’s because he’s the guy behind the Teensy family of microcontroller boards and several dozen extremely popular libraries for everything from displays to real time clocks. The biopotential signal library continues in [Paul]’s tradition of building very cool stuff with just code.

The hardware used in this project is TI’s ADS1294, a 24-bit ADC with either 4 or 8 channels. This chip is marketed as a medical analog front end with a little bit of ECG thrown in for good measure. [Paul] is only using the ADS1294 initially; more analog chips can be added later. It’s a great project in its own right, and when you include the potential applications of this library – everything from prosthetics to body sensors – it makes for an awesome Hackaday Prize entry.

The 2015 Hackaday Prize is sponsored by:

Commodore 64 Mods Make A Mobile Computer

May 22, 2015 by Anool Mahidharia 16 Comments

Some Commodore C64 owners and enthusiasts keep tinkering with their precious units, adding upgrades all the time. [wpqrek]’s latest upgrade to his C64 makes it totally portable – he added DC-DC converters to allow it to run off external battery sources.

He installed two separate DC-DC converters – one for 5V and another for 9V inside the enclosure. He opted for these high-efficiency converters because he planned to use batteries to power the device and wanted to maximize the juice he was extracting. He wired up a barrel jack socket to accept a 12V input, and another XT60 socket where he could attach a LiPo battery. A common 2200mAh RC battery is enough to power his C64 for 1.5 hours. To ensure the LiPo battery doesn’t get fully discharged, he’s added a simple buzzer circuit that starts beeping at around 3.3V.

How does just adding an external battery help make it portable? Well, he’s already added a small LCD display and a couple of other mods, that we featured in an earlier post. These earlier mod’s didn’t make the unit truly portable. Adding the latest hack does. Check out the video after the break.

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Forbidden Fruit Machine

May 22, 2015 by Anool Mahidharia 7 Comments

Here’s another example of how today’s rapid-prototyping technologies are allowing Artists and Craftsmen to create interactive works of art rapidly and easily. [Kati Hyypa] and [Niklas Roy] teamed up to transform a classic painting in to an interactive exhibit. It’s a painting of Adam, Eve and the apple with a joystick attached. Spectators can control the destiny of the apple with the joystick and thus explore the painting.

The “Forbidden Fruit Machine” is based on a painting called “The Fall of Man” created by [Cornelis Cornelisz van Haarlem] in 1592. The painting depicts Eve and Adam in the Garden of Eden, being tempted by the serpent to eat the forbidden fruit. A public domain, high-resolution scan of the painting is available for download from the Rijksmuseum Amsterdam. Starting with that, the arms were edited out, and replaced with articulated versions (mounted on acrylic) driven by servos. The apple was mounted on a X-Y gantry driven by two stepper motors. These are driven by a motor shield, which is controlled by an Arduino Uno. The Uno also controls a Music Maker shield to play the various audio tracks and sound effects. Finally, an additional Arduino Pro-Mini is used to control the LED lighting effects via a Darlington driver and also connect to the end stops for the X-Y gantry. The joystick is connected to the analog ports of the Uno.

The LED’s give clues on where to move the apple using the joystick, and pressing the red button plays an appropriate audio or sound effect. For example, pressing the button over the cat at Eve and Adam’s feet elicits a heart-breaking meow, while letting Eve eat the apple results in an even more dramatic effect including a thunder storm.

The machine is open source with code posted on Github and 3d files on Youmagine. Watch a video after the break. The artist’s names may be familiar to some some readers – that’s because both have had their earlier work featured on our blog, for example this awesome ball sucking machine and another one too.

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Arduino Vs Arduino: These Are Not The Droids…

May 22, 2015 by Elliot Williams 55 Comments

We’ve been trying to not pick favorites in the Arduino controversy, or at least remain open-minded to both sides of the story. Some businesses, on the other hand, are clearly aligning themselves. (Full text of e-mail below.)

Reader [Francisco Zabala], from cool robot-supplies store Acrobotic, got this e-mail from an Amazon distributor where he purchased some Arduinos “ages ago” and was angered enough at the brazen tone to drop us a line.

Thank you for our Arduino purchase from our Amazon.com store. We truly appreciate your business.

We are writing to let you know about an important change in Arduino products. The new website for Arduino is now officially Arduino.org. The old website (arduino.cc) should no longer be used.

All new Arduino hardware will be transitioned from the old Arduino.cc badging to the new Arduino.org badging. Please be aware that during this transition, you may receive Arduino hardware with either Arduino.cc or Arduino.org. Both are authentic Arduino-brand hardware.

If you use Arduino.org branded hardware on the old site, you may be presented with an error. Please use the new Arduino.org site.

We know for sure that Arduino SRL sent out a letter to distributors claiming that they were the real Arduino because they’ve been manufacturing the boards. Seeing a distributor recommend against the software at arduino.cc in such stark terms makes us wonder if there have been similar letters sent out concerning the IDE fork. Anyone have anything? Send us a tip if you do.

We find it a little ironic that when arduino.cc added the now-retracted popup that specifically targeted boards made by Smart Projects / Arduino SRL, that they opened themselves up to this sort of counter-attack: if you see an error popup, just switch over to the “new official” IDE. Oops. Good that it’s gone now.

Finally, we’ve got to say that “the old website should no longer be used” is pretty rich: we’re hackers, we use whatever software / IDE we like, thank you very much! No matter how the legal battles end up, and no matter who tells you to use what codebase, the beauty of open source is that it’s up to you, and not them. Hack on, y’all!

Thanks, [Francisco] for the tip.

Tessel 2, A $35 Linux Computer That’s Truly Open Source

May 22, 2015 by Brian Benchoff 22 Comments

We’ve seen the first version of the Tessel a few years ago, and it’s still an interesting board: an ARM Cortex-M3 running at 180MHz, WiFi, 32 Megs of both Flash and RAM, and something that can be programmed entirely in JavaScript or Node.js. Since then, the company behind Tessel, Technical Machines, has started work on the Tessel 2, a board that’s continuing in the long tradition of taking chips from WiFi routers and making a dev board out of them. The Tessel 2 features a MediaTek MT7620 running Linux built on OpenWRT, Ethernet, 802.11bgn WiFi, an Atmel SAMD21 serving as a real-time I/O coprocessor, two USB ports, and everything can still be controlled through JavaScript, Node, with support for Rust and other languages in the works.

Instead of going the usual route and determining the future of Tessel through market research and the apparent pragmatism of whoever happens to be in charge, this week Technical Machines did something wonderful: the ownership and direction of the Tessel Project is now independent of Technical Machine. This makes Tessel a completely open source and community driven platform for I0T, robots, and whatever else would benefit from an open source community disconnected from hardware.

The Tessel project is completely disconnected from manufacturers, something the Arduino project has been struggling with for the last few years, unbeknownst to most of the founders for most of that time. It’s a boon for the open source community, and something that should see an incredible uptake in the next few months.