The Aluminum Wiring Fiasco

Someone who decides to build a house faces a daunting task. It’s hard enough to act as the general contractor for someone else, but when you decide to build your own house, as my parents did in the early 1970s, it’s even tougher. There are a million decisions to make in an information-poor and rapidly changing environment, and one wrong step can literally cast in stone something you’ll have to live with forever. Add in the shoestring budget that my folks had to work with, and it’s a wonder they were able to succeed as well as they did.

It was a close call in a few spots, though. I can recall my dad agonizing over the wiring for the house. It would have been far cheaper to go with aluminum wiring, with the price of copper wire having recently skyrocketed. He bit the bullet and had the electrician install copper instead, which ended up being a wise choice, as houses that had succumbed to the siren call of cheaper wiring would start burning down all over the United States soon thereafter.

What happened in the late 60s and early 70s in the residential and commercial electrical trades was an expensive and in some cases tragic lesson in failure engineering. Let’s take a look at how it all happened.

Continue reading “The Aluminum Wiring Fiasco”

3D Printed Bicycle Tire Not Full Of Hot Air

To show off its new TPU filament called PRO FLEX, BigRep GmbH posted a video showing a 3D printed bike tire that uses a flexible plastic structure instead of air. The video shows them driving the bike around Berlin.

According to the company, the filament will allow the creation of a large number of industrial objects not readily built with other types of plastic. Their release claims the material has high temperature resistance, low temperature impact resistance, and is highly durable. Applications include gear knobs, door handles, skateboard wheels, and other flexible parts that need to be durable.

The material has a Shore 98 A rating. By way of comparison, a shoe heel is typically about 80 on the same scale and an automobile tire is usually around 70 or so. The hard rubber wheels you find on shopping carts are about the same hardness rating as PRO FLEX.

Obviously, a bicycle tire is going to take a big printer. BigRep is the company that makes the BigRep One which has a large build volume. Even with a wide diameter tip, though, be prepared to wait. One of their case studies is entitled, “Large Architectural Model 3D Printed in Only 11 Days.” Large, in this case, is a 1:50 scale model of a villa. Not tiny, but still.

We’ve looked at other large printers in the past including 3DMonstr, and the Gigimaker. Of course, the latest trend is printers with a practically infinite build volume.

Continue reading “3D Printed Bicycle Tire Not Full Of Hot Air”

AH-1 Cobra Tap Handle Pours On The Fun

Ayn Rand said, “If it’s worth doing, it’s worth overdoing.” As far as we’re concerned those are words to live by, and something that’s exemplified by most of the posts on this site. She also said some really suspect stuff about the disabled and Native Americans and reality, but you’ve got to take the good with the bad and all that.

We don’t know how much Rand [Will Weber] has read, but we’re willing to bet he’d agree about overdoing it. He recently documented a very cool 3D printed tap handle that’s designed to look like the B8 flight stick from an AH-1 Cobra helicopter. But this is no static piece of plastic, in the video after the break, he demonstrates how each button on the flight stick triggers a different weapons sound effect.

The 3D print is separated up into a number of sections so that the stick can be assembled in pieces. Not only does this make it an easier print, it also allows for the installation of the electronics.

For the Arduino aficionados out there, we have some bad news. Rather than putting in a general purpose microcontroller, [Will] went the easy route and used an Adafruit Audio FX Mini Sound Board. These boards have their own onboard storage for the audio files and don’t require a microcontroller to function. It makes it super easy to add sound effects or even music to your projects; just pair it with a power supply, a couple of buttons, and a speaker.

The finish work on the printed parts looks excellent. We can only imagine how much fun [Will] had sanding inside all the little nooks and crannies to get such a smooth final result. While some might complain about the idea of a tap handle needing to be recharged occasionally, we think the satisfaction of firing off a few rockets every time you grab a glass is more than worth it.

While this isn’t the first unique tap handle we’ve covered here at Hackaday, it’s certainly the most flight-ready. Continue reading “AH-1 Cobra Tap Handle Pours On The Fun”