Improving 3D Printed Gears With… Hot Water

July 3, 2016 by Donald Papp 44 Comments

Being able to print out custom gears is one area where 3D printing can really shine, and [Karl Lew] has been busy doing exactly that with pinion gears printed in PLA and mounted to stepper motor shafts, but there are tradeoffs. Pinion gears need to grip a motor shaft tightly – normally done with a screw through the gear and onto the motor shaft. But a motor and its shaft can get quite warm when doing a lot of work, and a tight screw on a hot motor’s shaft will transmit that heat into the PLA, which can then deform.

[Karl Lew] managed to improve things in an unusual way: using a hot water bath to anneal the gear while it is attached to the stepper shaft. Annealing PLA has the effect of increasing the crystallinity of the material, which – according to an article going into some detail about the process of annealing PLA – increases stiffness, strength, and heat deflection. The annealing process also shrinks the part slightly, which happens to result in a very tight joint made between the gear and the slotted stepper shaft if the gear is annealed while connected to the motor.

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Bringing A Teletype Into The 21st Century

July 3, 2016 by Brian Benchoff 9 Comments

Before modern CRTs with ancient VGA connectors, and before fancy video terminals, the display for computers large and slightly smaller was the Teletype. While many of these Teletypes were connected directly, they were designed to be a remote terminal, connected through Ma Bell’s network. [NeXT] over on the Vintage Computer Forums is bringing the iconic ASR33 Teletype into the 21st century by giving this old display a modern way to connect to the outside world.

If you ever see a Teletype in action, it will be connected to a local machine. This was certainly not always the case. The Teletype was designed to connect to remote systems. [NeXT]’s Teletype came with a Call Control Unit designed for Telex lines, which do not exist anymore. Modems for the ASR33 existed, but good luck finding one. Lucky for [NeXT], nearly every modem ever made is backwards-compatible with the Bell Dataphone, one of the standard ways of plugging a Teletype into a phone line. All [NeXT] had to do was put a modem inside this Teletype.

With relays, transistors, LEDs, and a lot of perfboard, [NeXT] successfully built a circuit that would interface the Teletype’s Call Control Unit to a Hayes Smartmodem tucked away inside the stand. Believe it or not, this is an exceptionally useful build; if you ever find a Teletype tucked away in the back of an old office, in a surplus shop, or on Craigslist, odds are it won’t be compatible with any modern electronics. That’s not to say land lines are particularly modern, but since there’s a microcontroller included in the new circuitry, it’s relatively easy to add a USB port to this ancient terminal.

You Can Learn A Lot From A Candle

July 3, 2016 by Dan Maloney 19 Comments

Beginning in 1827, [Michael Faraday] began giving a series of public lectures at Christmas on various subjects. The “Christmas Lectures” continued for 19 years and became wildly popular with upper-class Londoners. [Bill Hammack], aka [The Engineer Guy], has taken on the task of presenting [Faraday]’s famous 1848 “The Chemical History of a Candle” lecture in a five-part video series that is a real treat.

We’ve only gotten through the first episode so far, but we really enjoyed it. The well-produced lectures are crisply delivered and filled with simple demonstrations that drive the main points home. [Bill] delivers more or less the original text of the lecture; some terminology gets an update, but by and large the Victorian flavor of the original material really comes through. Recognizing that this might not be everyone’s cup of tea, [Bill] and his colleagues provide alternate versions with a modern commentary audio track, as well as companion books with educational guides and student worksheets. This is a great resource for teachers, parents, and anyone looking to explore multiple scientific disciplines in a clear, approachable way.

If there were an award for the greatest scientist of all time, the short list would include [Faraday]. His discoveries and inventions in the fields of electricity, magnetism, chemistry, and physics spanned the first half of the 19th century and laid the foundation for the great advances that were to follow. That he could look into a simple candle flame and see so much is a testament to his genius, and that 150 years later we get to experience a little of what those lectures must have been like is a testament to [Bill Hammack]’s skill as an educator and a scientist.

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Custom Firmware Unlocks Fitness Tracker

July 3, 2016 by Elliot Williams 17 Comments

[Mikhail] sent us a teaser video for a hack he’d done (embedded below). He takes a Bluetooth LE fitness tracker dongle and reflashes it spit out the raw accelerometer data and trigger events. He then wrote a phone app that receives the data and uses the device as an alarm, an on/off switch, a data-logging device, and more.

We thought it was cool enough that we asked [Mikhail] for more detail, and he delivered in spades! Inside the device is a Nordic NRF51822, their ARM Cortex + Bluetooth chip, an accelerometer, and a bunch of LEDs. [Mikhail] mapped out the programming headers, erased the old flash, and re-filled it with his own code. He even added over-the-air DFU re-flashing capability so that he wouldn’t have to open up the case again.

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The (Copper) Crystal Method

July 3, 2016 by Al Williams 43 Comments

One of the staples of kitchen chemistry for kids is making sugar crystals or rock candy. Why not? It is educational and it tastes good, too. [Science with Screens] has a different kind of crystal in mind: copper crystals. You can see the result in the video below.

To grow pure metal crystals, he used copper wire and copper sulfate. He also used a special regulated power supply to create a low voltage to control the current used to form the crystal. The current needed to be no more than 10mA, and an LM317 holds the voltage constant. However, that regulator only goes as low as 1.25V, so diodes cut a volt off the output.

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Brasilia Espresso Machine PID Upgrade Brews Prefect Cup Of Energy

July 3, 2016 by Moritz Walter 20 Comments

Coffee, making and hacking addictions are just bound to get out of control. So did [Rhys Goodwin’s] coffee maker hack. What started as a little restoration project of a second-hand coffee machine resulted in a complete upgrade to state of the art coffee brewing technology.

The Brasilia Lady comes with a 300 ml brass boiler, a pump and four buttons for power, coffee, hot water and steam. A 3-way AC solenoid valve, wired directly to the buttons, selects one of the three functions, while a temperamental bimetal switch keeps the boiler roughly between almost there and way too hot.

To reduce the temperature swing, [Rhys] decided to add a PID control loop, and on the way, an OLED display, too. He designed a little shield for the Arduino Nano, that interfaces with the present hardware through solid state relays. Two thermocouples measure the temperature of the boiler and group head while a thermal cut-off fuse protects the machine from overheating in case of a malfunction.

Also, the Lady’s makeup received a complete overhaul, starting with a fresh powder coating. A sealed enclosure along with a polished top panel for the OLED display were machined from aluminum. [Rhys] also added an external water tank that is connected to the machine through shiny, custom lathed tube fittings. Before the water enters the boiler, it passes through a custom preheater, to avoid cold water from entering the boiler directly. Not only does the result look fantastic, it also offers a lot more control over the temperature and the amount of water extracted, resulting in a perfect brew every time. Enjoy [Rhys’s] video where he explains his build:

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Hackaday Prize Entry: A Minimal ATtiny Voltage And Frequency Counter

July 2, 2016 by Jenny List 4 Comments

Sometimes when you build something it is because you have set out with a clear idea or specification in mind, but it’s not always that way. Take [kodera2t]’s project, he set out to master the ATtiny series of microcontrollers and started with simple LED flashers, but arrived eventually at something rather useful. An ATtiny10 DVM and DFM all-in-one with an i2c LCD display and a minimum of other components.

The DFM uses the ATtiny’s internal 16 bit timer, which has the convenient property of being able to be driven by an external clock. The frequency to be measured drives the timer, and the time it returns is compared to the system clock. It’s not the finest of frequency counters, depending as it does on the ATtiny’s clock rather than a calibrated crystal reference, but it does the job.

The results are shown in the video below, and all the code has been posted in his GitHub repository. We can see that there is the basis of a handy little instrument in this circuit, though with the price of cheap multimeters being so low even a circuit this minimal would struggle to compete on cost.

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