How To Build Anything Out Of Aluminum Extrusion And 3D Printed Brackets

May 8, 2018 by Roger Cheng 42 Comments

The real power of 3D printing is in infinite customization of parts. This becomes especially powerful when you combine 3D printing with existing materials. I have been developing a few simple tricks to make generic fasteners and printed connectors a perfect match for aluminum extrusion, via a novel twist or two on top of techniques you may already know.

Work long enough with 3D printers, and our ideas inevitably grow beyond our print volume. Depending on the nature of the project, it may be possible to divide into pieces then glue them together. But usually a larger project also places higher structural demands ill-suited to plastic.

Those of us lucky enough to have nice workshops can turn to woodworking, welding, or metal machining for larger projects. Whether you have that option or not, aluminum extrusion beams provide the structure we need to go bigger and to do it quickly. And as an added bonus, 3D printing can make using aluminum extrusion easier and cheaper.

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Alexa, Attack Intruders

May 8, 2018 by Richard Baguley 3 Comments

If our doom at the hands of our robot overlords is coming, I for one welcome the chance to get a preview of how they might go about it. That’s the idea behind Project Icarus, an Alexa-enabled face-tracking Nerf turret. Designed by [Nick Engmann], this impressive (or terrifying) project is built around a Nerf Vulcan, a foam dart firing machine gun mounted on a panning turret that is hidden behind a drop-down cabinet door. This is connected to a Pi Zero equipped with a Pi camera. The Zero is running OpenCV and Google Firebase, which connects it with Amazon’s Alexa service.

It works like this: you say “Alexa, open Project Icarus”. Through the Alexa skill that [Nick] created, this connects to the Pi and starts the system. If you then say “Alexa, activate alpha”, it triggers a relay to open the cabinet and the Nerf gun starts panning around, while the camera mounted on the top of it searches for faces. The command “Alexa, activate beta” triggers the Nerf to open fire.

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Is That A Tweet On Your Belt Buckle Or Are You Just Happy To See Me?

May 8, 2018 by Dan Maloney 8 Comments

What a time to be alive! The range of things you never knew you needed but absolutely must have expands at a breakneck pace, such that it’s now possible to pick up a belt buckle with an embedded LED matrix to scroll messages. We have no idea what the use case for something like this is, but some people will buy anything.

One such person was a friend of [Brian Moreau], who doubled down after being gifted the glowing bauble by turning it into a WiFi enabled Tweet-scrolling belt buckle. It appears to be a just for fun project, and to be honest one would need a heck of a belt for the buckle after his mods. He added an ESP8266 to take care of monitoring his Twitter account and driving the display on the belt buckle, a non-trivial task given that the thing is programmed with only two buttons that scroll through characters to compose a message. The microcontroller might have fit inside the original buckle or only added a little to its bulk, but [Brian] decided to replace the two coin cells powering it with an external 6-volt battery pack. That required a buck converter to power the ESP, so the whole thing ended up being thrown in a case and acting more like a neat display than a flashy fashion statement.

We’d bet some tradeoffs could be made to reduce the bulk and get that buckle back where it belongs, though. Once it does, maybe it’ll be part of a complete LED-laden ensemble, from head to toe.