Inside A Vintage Oven Controlled Crystal Oscillator

February 1, 2025 by Maya Posch 8 Comments

Crystal oscillators are incredibly useful components, but they come with one little snag: their oscillation is temperature-dependent. For many applications the relatively small deviation is not a problem, but especially for precision instruments this is a deal breaker. Enter the oven controlled crystal oscillator, or OCXO. These do basically what it says on the tin, but what’s inside them? [Kerry Wong] took apart a vintage Toyocom TCO-627VC 10 MHz OCXO, revealing a lot more complexity than one might assume.

Inside the insulated enclosure there is of course the crystal oscillator itself, which has a heating coil wrapped around it. Of note is that other OCXOs that [Kerry] took apart had more insulation, as well as other ways of providing the thermal energy. In this particular unit a thermistor is attached to the crystal’s metal case to measure its temperature and provide feedback to the heating circuit. The ICs on the PCB are hard to identify due to the conformal coating, but at least one appears to be a 74LS00, alongside a 78L05 voltage regulator which reduces the 12V input voltage.

As an older OCXO it probably is a lot chunkier than newer units, but the basic principle remains the same, with a heating loop that ensures that the crystal inside the unit remains at the same temperature.

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Using Microwave Heating To Locally Anneal CNT-Coated FDM Prints

February 1, 2025 by Maya Posch 19 Comments

The CNT coating between the layers is heated with microwaves to locally anneal. (Credit: Sweeney et al., Science Adv., 2017)

Layer adhesion is one of the weak points with FDM 3D printing, with annealing often recommended as a post-processing step. An interestingly creative method for this was published in Science Advances back in 2017, featuring the work of researchers at Texas A&M University and citing previous work by other teams. In the paper by [Charles B. Sweeney] et al, they describe how they coated PLA filament with carbon nanotubes (CNTs), resulting in this CNT being distributed primarily between the individual layers of polymer.

This is useful because CNTs are quite sensitive to microwave radiation, resulting in the conversion to thermal energy, i.e. heat. Compared to traditional annealing where the entire part is placed into an oven or similar, this microwave-based heating – or locally induced RF (LIRF) as they call this method – localizes the heat to the interface between two layers.

The advantages of this approach are that it doesn’t change the dimensions of the part noticeably, it’s faster and more efficient, and the annealing between layers approaches the strength of traditional manufacturing. Unfortunately not too much seems to have happened with this approach since then, but considering that both CNTs (single & double-walled) and microwaves are readily available, there’s not much standing in the way of replicating these results.

Could Non-Planar Infill Improve The Strength Of Your 3D Prints?

February 1, 2025 by Lewin Day 24 Comments

When you’re spitting out G-Code for a 3D print, you can pick all kinds of infill settings. You can choose the pattern, and the percentage… but the vast majority of slicers all have one thing in common. They all print layer by layer, infill and all. What if there was another way?

There’s been a lot of chatter in the 3D printing world about the potential of non-planar prints. Following this theme, [TenTech] has developed a system for non-planar infill. This is where the infill design is modulated with sinusoidal waves in the Z axis, such that it forms a somewhat continuous bond between what would otherwise be totally seperate layers of the print. This is intended to create a part that is stronger in the Z direction—historically a weakness of layer-by-layer FDM parts.

Files are on Github for the curious, and currently, it only works with Prusaslicer. Ultimately, it’s interesting work, and we can’t wait to see where it goes next. What we really need is a comprehensive and scientific test regime on the tensile strength of parts printed using this technique. We’ve featured some other neat work in this space before, too. Video after the break.

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Taking A $15 Casio F91W 5,000 Meters Underwater

February 1, 2025 by Maya Posch 42 Comments

When considering our favorite spy movies and kin that involve deep-sea diving, we’d generally expect to see some high-end watch that costs thousands of dollars and is specially engineered to withstand the immense pressures kilometers below the ocean’s surface. Yet what about a humble Casio F91W that can be bought for about $15 if it’s the genuine article and not one of the millions of fakes? Over at the Watches of Espionage site they figured that they’d dress up one of these famous watches to give it the best possible shot at surviving the crushing pressures at a depth of 5 km.

The actual modification to the F91W was pretty mild, involving nothing but a ‘hydro-mod’ whereby oil is used to replace the air inside the watch case. Since oil is incompressible, nothing bad should happen to the watch. Theoretically at least. The Watch-Under-Test (WUT) was strapped to a US Navy’s CURV 21 remotely operated vehicle and dunked into the ocean before starting its descend into the inky darkness of the deep sea.

Although only hitting a measly 4,950 m, the watch survived just fine, showing that even if you’re a secret US operative on a deep-dive espionage mission, all you really need is one of these Casio watches.

RedBox In The 80s: Meet The VHS Vending Behemoth

February 1, 2025 by Lewin Day 15 Comments

Redbox was a company with a moderately interesting business model—it let you rent DVDs from automated kiosks. It’s an idea so simple it’s almost surprising it didn’t appear sooner. Only, it did—all the way back in the VHS age!

Meet the Video Vendor. YouTuber [SpaceTime Junction] was able to track down one of these rare machines, which apparently formerly served an Ohio rental outlet called Kohnen’s. It’s a monstrous thing that stands taller and about three times wider than traditional vending machines, and it could hold up to 320 tapes in its robotic magazine. It’s got lashings of woodgrain, a green-on-black CRT, and the beautiful kind of clicky keys that went away after the 1980s.

[SpaceTime Junction] has a bunch of videos up on the machine, and you even get to see it powered up. It’s a little difficult to see what’s going on, because the machine is something like nine feet wide and it’s all shot in vertical video. There isn’t a whole lot of content on these obscurities out there, so this is a great place to start. Apparently, there were recently a hundred or more of these found living in a Texas warehouse according to Reddit, so we might see more of these popping up online soon. [SpaceTime Junction] has toured that facility, too.

You can read more about the fall of Redbox, or the cleanup afterwards, in our prior coverage.

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Time Vs Money, 3D Printer Style

February 1, 2025 by Elliot Williams 28 Comments

A few months ago, Hackaday’s own Al Williams convinced me to buy a couple of untested, returned-to-manufacturer 3D printers. Or rather, he convinced me to buy one, and the incredible success of the first printer spurred me on to the second. TL;DR: Lightning didn’t strike twice, but I’d still rate it as worth my time. This probably isn’t a good choice for your first printer, but if you’ve done the regular maintenance on your first printer already, I’d recommend it for your second or twelfth.

As background, Al has been volunteering with local schools to teach a 3D printing summer class, and this means outfitting them with a 3DP lab on the dirt cheap. His secret is to buy last year’s model which has all of the features he needs – most importantly for the kids, automatic bed height probing – but to buy it from the scratch-and-dent shelf at Creality. Why? Because they are mid-grade printers, relatively new, but on deep discount.

How deep? I found an essentially endless supply of printers that retail for $300 on discount for $90 each. The catch? It might work, it might not. I bought my son one, because I thought that it would at least make a good project for us to work on together. Those plans were spoiled – it worked absolutely flawlessly from the moment we bolted it together, and he runs 24-hour jobs on the thing without fear. From the look of the build plate, it had been used exactly once and returned for whatever reason. Maybe the owner just didn’t want a 3D printer?

The siren song of straightforward success was too much for me to resist, and I picked another up to replace my aging A8 which was basically a kit for a 3D printer, and not a particularly good one at that, but could be made to work. My scratch-and-dent Creality came with a defective bed-touch sensor, which manifest itself as a random absolute refusal to print.

I took it apart, but the flaw is in the design of the V1 touch sensors – the solenoid requires more current to push down than the 3DP motherboard can reliably deliver. It works 100% of the time on my bench power supply, but in situ it fails about 30% of the time, even after hitting it with graphite and making sure everything is mechanically sound. Creality knows this and offers a free trade-in, just not for me. The new version of the Creality probe costs $50 new, but you can get cheap knock-off BL Touch models for $14. Guess what I did?

And guess what bit me? The cheapo touch probe descends a bit slower than the Creality version should, and the firmware is coded to time-out in an extra-short timeframe. Thankfully, Creality’s modifications to Marlin are all open source, and I managed to tweak and flash a new firmware that made it work 100% of the time, but this was at a cost of probably eight hours of bug-hunting, part-ordering, and firmware-compiling. That said, I got some nice extra features along the way, which is the advantage of a printer running open-source firmware.

So my $300 printer cost me $105, plus eight hours of labor. I only charge one coffee per hour for fun hardware debugging tasks, but you may have a different valuation. Taken together with my son’s printer, we have $600 worth of printer for under $200 plus labor, though, which starts to sound a little better.

Is gambling on an untested return 3D printer worth it? For us, I would say it was, and I’d do it again in a few years. For now, though, we’ve got three printers running and that’s all we need. Have you gone down this perilous path?

Casio Calculator Gets New Keyboard

February 1, 2025 by Al Williams 5 Comments

What do you do with a circa 1985 Casio FX-451 calculator with a bad keyboard? Well, if you are [Poking Technology], you transplant the inside of the calculator to a new custom keyboard. There are two videos that cover the process in detail, which you can watch below.

The calculator has a unique design. It looks like a simple calculator in a wallet. But the wallet opens to reveal an extended keyboard with all the scientific features onboard. Unsurprisingly, the membrane keys didn’t survive over four decades. Disassembling the unit was a challenge. Soldering wires to the keyboard lines was further complicated by the fact that some of the lines are on the back of the PCB and pass through to the top under the main IC.

The new keyboard is quite a bit larger than the original, making this more of a desk calculator, but that also means you can use high-quality keys. We’d love to see a 3D printed case to wrap it all up, but the bare PCB look has its charms, too.

If you can’t understand how [Poking] can love a calculator so much, you probably never owned an HP-41C, either. Of course, our retro calculator dreams also include Star Trek.

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