Year: 2020

Fancy Filament Joiner Has Promise, But Ultimately Fails

December 17, 2020 by 29 Comments

[Proper Printing] has been trying to 3D print rims for his car for quite some time. However, the size of the print has led to problems with filament spools running out prior to completion. This led to endless headaches trying to join several smaller lengths of filament in order to make a single larger spool. After his initial attempts by hand failed, a rig was built to try and bring some consistency to the process. (Video, embedded below.)

The rig consists of a heater block intended to melt the ends of two pieces of filament so that they can be fused together. A cheap set of brass calipers was modified with a tube in order to form a guide for the filament, ensuring that it gets bonded neatly without flaring out to a larger size. Fan coolers are then placed either side of the heating area to avoid turning the whole filament into a hot mess.

Unfortunately, the rig simply didn’t work. The initial design simply never got the filament hot enough, with the suspicion being that heat was instead being dumped into the calipers instead of the filament itself. Modifications to reduce this sadly didn’t help, and in the end, more success was had by simply holding a lighter below a length of brass tube.

While the project wasn’t a success, there’s still value in the learning along the way. We can’t see any fundamental reason why such a rig couldn’t be made to work, so if you’ve got ideas on how it could be improved, sound off in the comments. We’ve seen other successful builds using hair straighteners in a relatively simple setup, too.

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A SNES, Ray Tracing

December 17, 2020 by 8 Comments

A trick famously used by Nintendo to keep its slowly aging SNES console fresh against newer competition was to produce new games with extra support chips in the cartridge to push out hitherto-unthinkable performance. Chips such as the famous SuperFX gave us 3D polygonal graphics, but it would have been a few more years before even much faster platforms could achieve real-time ray-tracing. Nintendo may not have managed it, but here in 2020 [Ben Carter] has a SNES on his bench rendering a complex 3D ray-traced world.

Ray tracing refers to the practice of rendering a scene with accurate lighting by tracing the rays of light that go towards making each pixel. It can achieve results that even approach photorealism, but it remains an extremely computationally intensive job for any computer. To do this with a SNES he hasn’t resorted to a modern computer like the excellent Raspberry-Pi-based NES DOOM cartridge, instead he’s tried to create something that might have graced a Nintendo custom chip back in the 1990s. The tool may be a thoroughly modern DE10-Nano FPGA dev board, but what it implements could conceivably have been made as a 1990s-spec ASIC. In it are three ray tracing cores that do the work, but the final rendering is handled by the SNES itself. At 200 x 160 pixels and 256 colours it’s no graphical powerhouse, but the maximum frame rate of 30 fps makes it no slouch for the day. The video below the break supplies extra detail.

Perhaps an unexpected takeaway of the rendered scene lies in how of its era it seems. It comes from an age in which checker-board floors, mirrored balls, and azure blue skies looked so futuristic, and just before the likes of Toy Story redefined what the general public might expect from 3D rendering. If Nintendo had produced a ray-traced SNES game using a chip like this one, it would have certainly been a defining moment for gaming in that decade.

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Skittle Sorter Makes Long Task Shorter

December 16, 2020 by 11 Comments

One of the most common complaints fielded by the agents of Big Candy regards the non-homogenous nature of their products. Skittles and M&Ms are two egregious offenders in this area, and it’s left up to the determined consumer to handle sorting these candies themselves. Of course, you can always do it by hand, but as we all know – machines will do the work.

This Skittle sorter is the creation of [Lewis] of [DIY Machines], and it’s a build targeted at the beginner level. Constructed out of cardboard, it uses a pair of servos to handle the transport of the candies into their requisite colored bins, via a rotating disc and chute. Skittles are scanned with a TCS34725 color scanner hooked up to an Arduino Nano, which changes the angle of the output chute to dump the candy in the proper location. The hopper is able to handle a standard 180 gram bag of Skittles without problems.

[Lewis] does a great job explaining each stage of the build, from the mechanical and electronic side of things, to the required calibrations to make everything play together nicely. The project teaches builders a multiude of useful lessons, like how to use limit switches and other concepts of automation.  We’ve featured [Lewis] on these pages before, too; his stylish shelf clock is a particular delight. Video after the break.

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Learn Compilers Online From Cornell

December 16, 2020 by 29 Comments

It sounds like the start of a joke, but what’s the difference between taking Cornell’s CS6120 online and in-person? The instructor, [Adrian Samspon] notes that the real class has deadlines, an end-of-semester project, and a discussion board that is only open to real-life students. He also notes that you only earn “imagination credits.”

Still, this is a great opportunity to essentially audit a PhD-level computer science class on a fascinating topic. The course consists of videos, papers, and open source projects using LLVM and a custom internal representation based on JSON that is made for the class. It is all open source, too. You do however need access to the papers, some of which are behind paywalls. Your local library can help if you can’t otherwise find copies of the papers.

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Automatic Sanitizer For Your Cupholder

December 16, 2020 by 6 Comments

Why is it so hard to remember to use hand sanitizer between going into the store and driving back home? We tried hanging a bottle off the windshield wiper stalk, but it gets in the way and is hard to use and share with passengers. The ideal thing would be to have a hands-free pump in the car that reminds you to use it.

You don’t have to wire this to the ignition or anything — all you have to do is power it with the cigarette lighter (or straight-up outlet, if you’re lucky). Every time you turn the key, this pump powers up and performs a little song to remind you to use it. Electronically speaking, it couldn’t be simpler — an Arduino UNO reads your hand from the distance sensor and activates a servo that dispenses three short pumps of isopropyl alcohol. Check it out in action after the break.

Want a hands-free solution for the house? Just build something you can step on.

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Building Distributed Mode Loudspeakers With Plywood

December 16, 2020 by 18 Comments

Distributed-mode loudspeakers work rather differently from the typical drivers used in 99% of applications. Instead of using piston-like motion to create sound waves, they instead rely on exciting an entire panel to vibrate and thus produce sound. [JGJMatt] decided to build a pair of bookshelf-sized units, with great results.

The build begins with a pair of 44mm DML exciters, readily available online. These had to be modified to remove their stock metal mounting plates that degraded the sound output in early tests. Instead, 3D printed pieces were used to mount the exciters to the 3mm plywood boards, which were lasercut to act as the main DML panels. Additionally, whizzer cones were fitted to the panels in an effort to further boost the high frequency response of the speakers. The speaker stands are assembled out of more 3D printed pieces and aluminium rods, giving a clean, modern look to the final product.

The performance of the speakers is admirable based on the test video, though [JGJMatt] notes that they should be paired with a subwoofer in use as the DML units do not readily produce frequencies below 100Hz. We’ve seen similar builds before on a larger scale, too. Video after the break.

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Enormous CNC Router Uses Clever Tricks To Improve Performance

December 16, 2020 by 32 Comments

CNC machines made from wood and 3D-printed parts may be popular, but they aren’t always practical from a precision and repeatability standpoint. This is especially true as the machines are scaled up in size, where the compliance of their components starts to really add up. But can those issues be resolved? [jamie clarke] thinks so, and he’s in the process of building a CNC router that can handle a full sheet of plywood. (Video, embedded below.)

This is very much a work in progress, and the videos below are only the very beginning of the process. But we found [jamie]’s build interesting even at this early point because he has included a few clever tricks to control the normal sources of slop that plague larger CNC machines. To provide stiffness on a budget, [jamie] went with a wooden torsion-box design for the bed of his machine. It’s the approach taken by the Root CNC project, which is the inspiration for this build. The bed is formed from shallow boxes that achieve their stiffness through stressed skins applied to rigid, lightweight frames.

Upon the torsion-box bed are guide rails made from commodity lengths of square steel tubing. Stiff these may be over short lengths, but over the three meters needed to access a full sheet of plywood, even steel will bend. [jamie]’s solution is a support that moves along with the carriage, which halves the unsupported length of the beam at all points of travel. He’s using a similar approach to fight whip in the ball screw, with a clever flip-down cradle at the midpoint of the screw.

So far, we’re impressed by the quality of this build. We’re looking forward to seeing where this goes and how well the machine performs, so we’re paying close attention to the playlist for updates. At an estimated build cost of £1,500, this might be just the CNC build you’ve been looking for.

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