Origami-Inspired, Self-locking Structures With 3D Printing

Researchers recently shared details on creating foldable, self-locking structures by using multi-material 3D printing. These origami-inspired designs can transition between flat and three-dimensional forms, locking into place without needing external support or fasteners.

The 3D structure of origami-inspired designs comes from mountain and valley fold lines in a flat material. Origami designs classically assume a material of zero thickness. Paper is fine, but as the material gets thicker things get less cooperative. This technique helps avoid such problems.

An example of a load-bearing thick-film structure.

The research focuses on creating so-called “thick-panel origami” that wraps rigid panels in a softer, flexible material like TPU. This creates a soft hinge point between panels that has some compliance and elasticity, shifting the mechanics of the folds away from the panels themselves. These hinge areas can also be biased in different ways, depending on how they are made. For example, putting the material further to one side or the other will mechanically bias that hinge to fold into either a mountain, or a valley.

Thick-panel origami made in this way paves the way towards self-locking structures. The research paper describes several different load-bearing designs made by folding sheets and adding small rigid pieces (which are themselves 3D printed) to act as latches or stoppers. There are plenty of examples, so give them a peek and see if you get any ideas.

We recently saw a breakdown of what does (and doesn’t) stick to what when it comes to 3D printing, which seems worth keeping in mind if one wishes to do some of their own thick-panel experiments. Being able to produce a multi-material object as a single piece highlights the potential for 3D printing to create complex and functional structures that don’t need separate assembly. Especially since printing a flat structure that can transform into a 3D shape is significantly more efficient than printing the finished 3D shape.

Creators demonstrating their Jedi Watch

Walkie Talkies, Jedi Style: Building A Communicator

Playing Star Wars Outlaws sparked an idea with [3DSage]: why not recreate the game’s wrist communicator as a functioning gadget? Inspired by the relatively simplistic design, he and his friend Ben set out to build their own device to take to Galaxy’s Edge in Disneyland. Armed with an arsenal of tools—3D printers, CNC machines, and soldering irons—he aimed to turn imagination into reality.

After ordering multiple walkie-talkies, they meticulously tested each one for audio quality, circuit board size, and compatibility with custom components. The ‘world’s tiniest walkie-talkie’ had potential but demanded creative modifications, including disassembling and resoldering components. They crafted their own circuit board and designed a 3D printed housing to fit both electronics and style. For the finishing touch, they weathered the device with paints and even glow-in-the-dark accents, making it authentic to the Star Wars universe. Even Chewbacca himself gave one a thumbs-up!

Weathering goes a long way towards creating a convincing prop — it can turn a bundle of pipes and some foam blocks into a movie-ready WWII machine gun.

Continue reading “Walkie Talkies, Jedi Style: Building A Communicator”

Left: the traces of a flashy paper Christmas tree. Right: the finished tree on cardstock.

Flashy Paper Christmas Tree Does It With A 555

‘Tis the season for holiday hacks, and [Ben Emmett] is here to remind us that we don’t necessarily need a fancy microcontroller in order to make flashy fun things happen.

Smoothing down the copper traces with a guitar pick.
Smoothing down the copper traces with a guitar pick.

Take this Christmas tree for example, which uses a 555 timer and a CB4017 decade counter in order to drive some blinking LEDs. The ICs are through-hole, making the circuit fairly accessible to new players, but there are a few SMD components that need soldering as well. (More on that later.)

Here, the 555 acts like a clock and drives a square wave. Using the clock as input, the decade counter toggles the output pins one after the other, driving the LEDs to blink in turn. Since there are only eight lights, there is a pause in the light-up pattern, but that could be fixed by wiring decade counter output #9 to the reset pin.

Although function was the main focus circuit-wise, [Ben] managed to lay the traces in the shape of a Christmas tree, which looks great. Having done a similar project in the past, he discovered that the craft cutting machine prefers thick traces and wider spaces between them. This is largely why [Ben] chose to use through-hole ICs.

After laying everything out in KiCad, [Ben] exported the copper layer image for use on the cutting machine. Once it was all cut out, he put it on transfer tape to weed out the extra copper, and get the traces onto cardstock, the final substrate.

This is such a fun project, and we love that the CR2032 that powers it also acts as the stand in its vertical holder. Hit up GitHub if you want to make one for yourself. Want something even more 3D? Check out this hollow tree we saw a few years ago.

Apple Newton Gets Rebuilt Battery Pack

We all carry touch screen computers around in our pockets these days, but before the smartphone revolution, there was the personal digital assistant (PDA). While it wasn’t a commercial success, one of the first devices in this category was the Apple Newton. Today they’re sought after by collectors, although most of the ones surviving to this day need a bit of rework to the battery pack. Luckily, as [Robert’s Retro] shows, it’s possible to rebuild the pack with modern cells.

By modern standards, the most surprising thing about these battery packs is both that they’re removable and that they’re a standard size, matching that of AA batteries. The Newton battery pack uses four cells, so replacing them with modern rechargeable AA batteries should be pretty straightforward, provided they can be accessed. This isn’t as easy, though. In true Apple fashion the case is glued shut, and prying it apart can damage it badly enough so it won’t fit back in the tablet after repair is complete. The current solution is to cut a hatch into the top instead and then slowly work on replacing the cells while being careful to preserve the electronics inside.

[Robert’s Retro] also demonstrates how to spot weld these new AA batteries together to prepare them for their new home in the Newton case. With the two rows fastened together with nickel strips they can be quickly attached to the existing electrical leads in the battery pack, and from there it’s just a matter of snapping the batteries into the case and sliding it back into the tablet. If you’re looking for something a bit more modern, though, we’d recommend this Apple tablet-laptop combo, but it’s not particularly easy on the wallet.

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The Stern-Gerlach Experiment Misunderstood

Two guys — Stern and Gerlach — did an experiment in 1922. They wanted to measure magnetism caused by electron orbits. At the time, they didn’t know about particles having angular momentum due to spin. So — as explained by [The Science Asylum] in the video below — they clearly showed quantum spin, they just didn’t know it and Physics didn’t catch on for many years.

The experiment was fairly simple. They heated a piece of silver foil to cause atoms to stream out through a tiny pinhole. The choice of silver was because it was a simple material that had a single electron in its outer shell. An external magnet then pulls silver atoms into a different position before it hits some film and that position depends on its magnetic field.

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Hack On Self: How’d My Day Go?

Humans are well overdue for a technological revolution – not a profit-driven one like we’re having now, a human-centric one. Sci-fi is wonderful for having your brain run wild. Over the last century, we’ve had writers try and imagine what world would’ve had looked like if a new technology were to address different aspects of human condition, or, work to undercut us all in yet unseen ways, for a change.

Quite a few leading HaD projects have clear sci-fi inspiration, too, and same goes for a large number of Hackaday Prize entries. Over here, we live for fantasy made reality through skill, wit, and insights.

Ever got a sci-fi-esque dream that you’ve tried to implement with modern-day tech, only to fail because something fundamental was missing about how your phone/laptop/smartwatch functions? You’re not alone here, for sure – this describes a large chunk of my tech journey. In real life, you work with audience-tailored devices, the few fun usecases pre-cooked into the hardware-firmware blob.

Still, how much can you build on top of a consumer device? Alternative OSes that liberate you from the trend of enshittification, for instance, that one’s brilliant and a lifeline for preserving one’s sanity. Alternative platforms that bring a reprieve from a modern combative and ad-filled social media environment, sure. Still, feels limited

How about diary keeping? Personal diaries are really rad, aren’t they? Surely, that one’s a low-hanging fruit? Continue reading “Hack On Self: How’d My Day Go?”

Hackaday Podcast Episode 300: The Dwingeloo 25 M Dish, A Dead-Tech Twofer, And Deconstructing PCBs

This week on the big 300th episode, Hackaday’s Elliot Williams and Kristina Panos teamed up to bring you the latest news, mystery sound, and of course, a big bunch of hacks from the previous week. So basically, business as usual.

First up in the news: it’s time for the Hackaday Europe 2025 call for proposals! Do you have a tale of hardware, firmware, or software that must be shared with the Hackaday crowd? Then this is your chance to regale us with a 20- or 40-minute talk. You know we love to hear new voices, so be sure to consider proposing a talk.

On What’s That Sound, it’s a results show week. Congratulations to [Kelvin] who was one of many that correctly identified it as the Wii startup sound. Kristina will just be over here with her Pikachu64 with the light-up cheeks.

Then it’s on to the hacks and such beginning with a rather nice reverse-engineering of the PS1, which surprisingly did it with a two-sided board. Then it’s on to a smartphone home server, magic eye images in a spreadsheet, and the math behind the music of 80s. Finally, we talk about disc cameras, the hovercraft revolution, and a whole mess of keyboards.

Check out the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

Download in DRM-free MP3 and savor at your leisure.

Continue reading “Hackaday Podcast Episode 300: The Dwingeloo 25 M Dish, A Dead-Tech Twofer, And Deconstructing PCBs”