Moving Big Stuff Without The Tears

It’s something that has probably happened to more than one of us over the years, there’s an unmissable opportunity at the machinery auction or on eBay, with the small snag that it weighs a ton and requires a flatbed truck to transport. A big lathe, a bandsaw, or the like.

The sensible option would be to hire a crane or a forklift to do the job, but cash is tight so at the appointed hour the truck turns up at the end of your driveway to meet you and as big a group of your friends as you could muster. You’re going to shift this thing with pure muscle power! If you grow up around any form of workshop-based small business it’s something you’ll no doubt be familiar with. Craftsmen seem to have a network for such moments, so just as the blacksmith might find himself helping the woodworker unload a huge saw bench, so might they both spend an unexpected afternoon at the engineering shop manhandling a lathe.

It came as a shock in a casual hackerspace conversation to realise how many times I’d been involved in such maneuvers at home, for friends, or at hackerspaces, and how that experience in doing so safely isn’t necessarily something that’s universal. Maybe it’s time to tell the story of moving big machines on limited resources. This is something that starts by thinking ahead and planning what you’ll need and where you’ll need it. Continue reading “Moving Big Stuff Without The Tears”

A Single-Watt Hydroponic Lighting System

Hydroponic systems are an increasingly popular way to grow plants indoors using a minimum of resources. Even some commercial farming operations are coming online using hydroponic growing techniques, as these methods consume much less water, land area, and other resources than traditional agricultural methods. The downside is that the required lighting systems often take an incredible amount of energy. That’s why [ColdDayApril] set up a challenge to grow a plant hydroponically using no more than a single watt.

The system is set up to grow a single pepper plant in what is known as a deep-water culture, where the plant is suspended in a nutrient solution which has everything it needs to grow. The lightning system is based around the Samsung LM301B which comes close to the physical limits for converting electricity into white light and can manage around 220 lumens. A special power supply is needed for these low-power diodes, and the light is efficiently directed towards the plant using a purpose-built reflective housing. By placing this assembly very close to the plant and adjusting it as it grows, [ColdDayApril] was able to take the pepper plant from seed to flowering in 92 days.

It’s worth noting that the rest of the system uses a little bit of energy too. A two watt fan helps circulate some air in the hydroponic enclosure, and deep-water systems usually require an air pump to oxygenate the water which uses another two watts. This is still an impressive accomplishment as most hobbyist builds use lighting systems rated in the hundreds of watts and use orders of magnitude more energy. But, if you’re willing to add some fish into the system you can mitigate some of the energy requirements needed for managing the water system even further.

3D Printed Heat Exchanger Uses Gyroid Infill For Cooling

3D printing allows the physical manufacturing of some unique geometries that are simply not possible with other processes. If you design around these strengths, it is possible to create parts that significantly outperform more conventional alternatives. With this in mind [Advanced Engineering Solutions] created a metal 3D printed heat exchanger that is half the size and four times the efficiency of the one it was designed to replace. Video after the break.

Gyroid infill splits an internal volume in two, perfect for heat exchangers.

Made from an aluminum alloy using a Laser Powder Bed Fusion (LPBF) machine, the heat exchanger is intended to cool transmission oil on military helicopters by using fuel as the coolant. Looking somewhat similar to a FabergĂ© egg, it uses gyroid “infill” for the actual heat exchange part. An interesting characteristic of gyroids is that it creates two separate intermeshed volumes, making them perfect for this application.

It was printed in one piece, without any removable support, just an internal lattice that supports the gyroids at the inlet and outlets. The only post-processing required was threading and surface cleanup on the ports. Since metal 3D printing is still too expensive to really allow many iterative prints, a significant amount of design and simulation time was put in before the first print.

Continue reading “3D Printed Heat Exchanger Uses Gyroid Infill For Cooling”