Fully Printed CNC On An IKEA Table

February 2, 2016 by Gerrit Coetzee 15 Comments

It seems that many 3D printer owners just aren’t getting the same buzz they used to off their 3D printers, and are taking steps to procure heavier machines. And making them in their home laboratories with, you guessed it, their 3D printers.

Following the pattern, [Michael Reitter], designed a 3D printable CNC around a IKEA MALM table. In order to span the length of the table for his X axis, he came up with a very cool looking truss assembly. The linear rails rest on top of the truss, and a carriage with the Z axis rides on the assembly. The truss has enough space in the center of it to neatly house some of the wiring. The Y-xis mounts on the side of the table.

Overall the mechanical design looks pretty solid for what it is, with all the rails taking their moments in the right orientation. We also like the work-piece hold downs that slide along the edge of the table. It even has a vacuum attachment that comes in right at the milling bit.

We’re not certain how much plastic this build takes, but it looks to be a lot. Monetarily, it will probably weigh in at a bit more than some other options. As many in the 3D printing world are discovering, sometimes there’s no reason not to leverage more mature industrial processes for lower cost large gains in accuracy and strength. Though, it’s pretty clear that one of the design goals of this project was to see how much one can get away with just a 3D printer, and we certainly can’t deny the appealing aesthetic of this CNC.

Video of it in action after the break.

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Making Parametric Models In Fusion 360

February 2, 2016 by Gerrit Coetzee 51 Comments

We all know and love OpenSCAD for its sweet sweet parametrical goodness. However, it’s possible to get some of that same goodness out of Fusion 360. To do this we will be making a mathematical model of our object and then we’ll change variables to get different geometry. It’s simpler than it sounds.

Even if you don’t use Fusion 360 it’s good to have an idea of how different design tools work. This is web-based 3D Modeling software produced by Autodesk. One of the nice features is that it lets me share my models with others. I’ll do that in just a minute as I walk you through modeling a simple object. Another way to describe what we’re going to learn is: How to think when modeling in Fusion 360.

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Super Thin ICs Are Coming

February 2, 2016 by Al Williams 17 Comments

An ordinary integrated circuit is made of layers of material. Typically a layer is made from some material (like silicon dioxide, polysilicon, copper, or aluminum). Sometimes a process will modify parts of a layer (for example, using ion implantation to dope regions of silicon). Other times, some part of the layer will be cut away using a photolithography process.

Researchers at MIT have a new technique that allows super thin layers (1-3 atoms thick) and–even more importantly–enables you to use two materials in the same layer. They report that they have built all the basic components required to create a computer using the technique.

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Experimental Gases, Danger, And The Rock-afire Explosion

February 2, 2016 by Adam Fabio 98 Comments

On the morning of September 26th, 2013 the city of Orlando was rocked by an explosion. Buildings shook, windows rattled, and Amtrak service on a nearby track was halted. TV stations broke in with special reports. The dispatched helicopters didn’t find fire and brimstone, but they did find a building with one wall blown out. The building was located at 47 West Jefferson Street. For most this was just another news day, but a few die-hard fans recognized the building as Creative Engineering, home to a different kind of explosion: The Rock-afire Explosion.

The Inventor and His Band of Robots

Many of us have heard of the Rock-afire Explosion, the animatronic band which graced the stage of ShowBiz pizza from 1980 through 1990. For those not in the know, the band was created by the inventor of Whac-A-Mole, [Aaron Fechter], engineer, entrepreneur and owner of Creative Engineering. When ShowBiz pizza sold to Chuck E. Cheese, the Rock-afire Explosion characters were replaced with Chuck E. and friends. Creative Engineering lost its biggest customer. Once over 300 employees, the company was again reduced to just [Aaron]. He owned the building which housed the company, a 38,000 square foot shop and warehouse. Rather than sell the shop and remaining hardware, [Aaron] kept working there alone. Most of the building remained as it had in the 1980’s. Tools placed down by artisans on their last day of work remained, slowly gathering dust.

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Building One Thing In China

February 2, 2016 by Brian Benchoff 34 Comments

Conventional wisdom dictates that if you need to make a million of something, you go to China. China is all about manufacturing, and there aren’t many other places on the planet that have the industry and government-subsidized shipping that will bring your product from China to people around the world. Building a million things in China is one thing, but what about building one thing? How do you create a working prototype of your latest product, and how do you make that prototype look like something that isn’t held together with zip ties and hot glue? The folks at Hatch Manufacturing have a guide for doing just that, and lucky for us, it’s a process that’s easy to replicate in any well-equipped shop.

In this tutorial/case study/PR blitz, Hatch Manufacturing takes on constructing a one-off smartphone. The Huaqiangbei markets in Shenzhen are filled with vendors selling smartphones of all shapes and sizes. If you want a miniature iPhone running Android, that’s no problem. If you want a phone that looks like a 1969 Dodge Charger with the Stars and Bars on top, you can find it in China. But how are all these phones made, and how do you show off a prototype to factories begging for business?

The answer, as is always the case, comes from one-off manufacturing. Building, assembling and reworking PCBs is a well-trodden path whose process could fill several volumes, but for this post, Hatch Manufacturing decided to focus on the plastics that go into a smartphone or tablet.

Once the case or enclosure is designed with a few CAD tools, a block of plastic is run through a mill. After that, it’s a matter of painting and finishing the latest smartphone that will show up in the Chinese market. Putting a professional finish on a block of plastic is something that will look familiar to anyone who has ever assembled a miniature plastic model. There’s priming, airbrushing, sanding, more painting, sanding, wet sanding, and still more sanding. After that comes polishing the plastic part to a fine finish. It is extraordinarily labor intensive work even for a skilled hand with the right equipment.

Once the plastics are done, the PCB, display, battery, and everything else comes together in a completely custom one-off prototype. It’s very similar to how this would be done in any small shop with a benchtop mill and a dozen grades of wet/dry sandpaper. It’s also something anyone can do, provided they have enough practice and patience.

Snooping On SIM Cards

February 2, 2016 by Elliot Williams 23 Comments

[Nils Pipenbrinck] has been working on a very interesting problem. The SIM card in your cellphone talks to the contactless near-field communication (NFC) chip through a cool protocol that we’d never hear of until reading his blog: single wire protocol (SWP).

The SIM card in your cellphone has only a limited number of physical connections — and by the time NFC technology came on the scene all but one of them was in use. But the NFC controller and the SIM need full-duplex communications. So the SWP works bi-directionally on just one wire; one device modulates the voltage on the line, while the other modulates the current, essentially by switching a load in and out.

This signalling protocol makes snooping on this data line tricky. So to start off his explorations with SWP, [Nils] built his own transceiver. That lead [Nils] to some very sensitive analog sniffer circuit design that he’s just come up with.

If you get interested in SWP, you’ll find the slides from this fantastic presentation (PDF) helpful, and they propose a solution very similar to the one that [Nils] ended up implementing. That’s not taking anything away from [Nils]’s amazing work: with tricky high-speed analog circuitry like this, the implementation can be more than half of the battle! And we’ll surely be following [Nils]’s blog to see where he takes this.

Banner image: An old version and a new version of the transceiver prototype.

Thanks to [Tim Riemann] for the tip!

Cramming A Pi Zero Into A USB Hub

February 1, 2016 by James Hobson 41 Comments

We kinda feel bad posting all these awesome hacks you can do with a Raspberry Pi Zero when we know most of our audience here probably doesn’t have one due to the backlog of orders… but regardless — here’s another one you can try — if you have one anyway. A Raspberry Pi USB Hub!

In case you didn’t know, Amazon has a series of electronics accessories called Amazon Basics — and they’re actually pretty good quality accessories. One of them is a 7-port, 4A USB hub. Looking at this [gittenlucky] figured he might just have enough room to fit a Pi Zero inside… and as it turns out. He did.

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