Better 3D-Printed Bridges Are Possible, With The Right Settings

November 5, 2025 by Donald Papp 16 Comments

The header image above shows a completely unsupported 3D-printed bridge, believe it or not. You’re looking at the bottom of the print. [Make Wonderful Things] wondered whether unsightly unsupported bridges could be improved, and has been busy nailing down remarkably high-quality results by exhaustive testing of different settings.

It all started when they thought that unsupported bridges looked a lot as though they were made from ropes stretched between two points. Unlike normal layers, these stretched extrusions didn’t adhere to their neighbors. They are too far apart from one another, and there’s no “squish” to them. But could this be overcome?

His experiments centered mainly around bridge printing speed, temperature, and bridge flow. That last setting affects how much the extrusion from the hot end is adjusted when printing a bridge. He accidentally increased it past 1.0 and thought the results were interesting enough to follow up on; it seemed that a higher flow rate when printing a bridge gave the nudge that was needed to get better inter-line adhesion. What followed was a lot of testing, finally settling on something that provided markedly better results than the stock slicer settings. Markedly better on his test pieces, anyway.

BF = Bridge flow, BS = Bridge printing speed (in mm/sec)

The best results seem to come from tweaking the Bridge Flow rate high enough that extrusions attach to their neighbors, printing slowly (he used 10 mm/sec), and ensuring the bridged area is as consistent as possible. There are still open questions, like some residual sagging at corners he hasn’t been able to eliminate, but the results otherwise look great. And it doesn’t even require laying one’s printer on its side!

All the latest is on the project page where you can download his test models, so if you’re of a mind to give it a try be sure to check it out and share your results. Watch a short video demonstrating everything, embedded just under the page break.

Thanks to [Hari] for the tip!

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Hacking Buttons Back Into The Car Stereo

November 5, 2025 by Tyler August 18 Comments

To our younger readers, a car without an all-touchscreen “infotainment” system may look clunky and dated, but really, you kids don’t know what they’re missing. Buttons, knobs, and switches all offer a level of satisfying tactility and feedback that touchscreens totally lack. [Garage Tinkering] on YouTube agrees; he also doesn’t like the way his aftermarket Kenwood head unit looks in his 2004-vintage Nissan. That’s why he decided to take matters into his own hands, and hack the buttons back on.

Rather than source a vintage stereo head unit, or try and DIY one from scratch, [Garage Tinkering] has actually hidden the modern touchscreen unit behind a button panel. That button panel is actually salvaged from the stock stereo, so the looks fit the car. The stereo’s LCD gets replaced with a modern color unit, but otherwise it looks pretty stock at the end.

Adding buttons to the Kenwood is all possible thanks to steering-wheel controls. In order to make use of those, the touchscreen head unit came with a little black box that translated the button press into some kind of one-wire protocol that turned out to be an inverted and carrier-less version of the NEC protocol used in IR TV remotes. (That bit of detective work comes from [michaelb], who figured all this out for his Ford years ago, but [Garage Tinkering] is also sharing his code on GitHub.) Continue reading “Hacking Buttons Back Into The Car Stereo” →

2025 Component Abuse Challenge: The Ever-Versatile Transistor As A Temperature Sensor

November 5, 2025 by Jenny List 19 Comments

One of the joys of writing up the entries for the 2025 Component Abuse Challenge has come in finding all the different alternative uses for the humble transistor. This building block of all modern electronics does a lot more than simply performing as a switch, for as [Aleksei Tertychnyi] tells us, it can also function as a temperature sensor.

How does this work? Simple enough, the base-emitter junction of a transistor can function as a diode, and like other diodes, it shows a roughly 0.2 volt per degree voltage shift with temperature (for a silicon transistor anyway). Taking a transistor and forward biasing the junction with a 33 K resistor, he can read the resulting voltage directly with an analogue to digital converter and derive a temperature reading.

The transistor features rarely as anything but a power device in the projects we bring you in 2025. Maybe you can find inspiration to experiment for yourself, and if you do, you still have a few days in which to make your own competition entry.

The Deadliest US Nuclear Accident Is Not What You Think

November 5, 2025 by Al Williams 42 Comments

When you think of a US Nuclear accident, you probably think of Three Mile Island. However, there have been over 50 accidents of varying severity in the US, with few direct casualties. (No one died directly from the Three Mile Island incident, although there are some studies that show increased cancer rates in the area.)

Indeed, where there are fatalities, it hasn’t been really related to the reactor. Take the four people who died at the Surry Nuclear Power Plant accident: they were killed when a steam pipe burst and fatally scalded them. At Arkansas Nuclear One, a 525-ton generator was being moved, the crane failed to hold it, and one person died. That sort of thing could happen in any kind of industrial setting.

But one incident that you have probably never heard of took three lives as a direct result of the reactor. True, it was a misuse of the reactor, and it led to design changes to ensure it can’t happen again. And while the incident was nuclear-related, the radiation didn’t kill them, although it probably would have if they had survived their injuries. Continue reading “The Deadliest US Nuclear Accident Is Not What You Think” →

SolidWorks Certification… With FreeCAD?

November 5, 2025 by Tyler August 26 Comments

There are various CAD challenges out there that come with bragging rights. Some, like the Certified Solid Works Professional Exam (CWSP) might actually look good on a resume. [Deltahedra] is apparently not too interested in padding his resume, nor does he have much interest in SolidWorks, and so decided to conquer the CWSP with FreeCAD in the name of open source — and to show us all how he did it.

Because these CAD exams are meant to show your chops with the program, the resulting video makes an awesome FreeCAD tutorial. Spoiler alert: he’s able to model the part, though it takes him about 15 minutes. After modeling the part, the CWSP exam needs you to find the mass of the part, which [Deltahedra] does with the FCInfo macro — which, of course, he shows us how to install and use. The second and third questions are similar: change some variables (it is a parametric modeling software, after all) and find the new mass. In a second exercise, he needs to modify the model according to a new drawing. Modifying existing models can sometimes be more difficult than creating them, but [Deltahedra] and FreeCAD pass with flying colors once again.

If you’re at all curious about what FreeCAD can do, this video is a really impressive demonstration of FreeCAD’s part modeling workbench. We’ve had a few FreeCAD guides of our on on Hackaday, like this one on reverse engineering STLs and this one on best practices in the software, but if you’d asked us before the release of v1.0 we’d never have guessed you could use it for a SolidWorks exam in 2025. So while there are kudos due to [Deltahedra], the real accolades belong to the hardworking team behind FreeCAD that has brought it this far. Bravo!

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Medieval Iron, Survivorship Bias And Modern Metallurgy

November 5, 2025 by Maya Posch 37 Comments

When you hear it said that “Modern steel is disposable by design”, your ears perk up, as you just caught the unmistakable sound of faux romanticism along with ‘lost ancient technology‘ vibes. Although it happens sometimes that we did lose something important, as with for example the ancient Roman concrete that turns out to have self-healing properties as a result of so-called hot mixing, this is decidedly an exception.

We nearly lost that technology because of the technological and scientific bonfire that was the prelude to a thousand years of darkness over Europe: called the Dark Ages, Middle Ages as well as the medieval period. Thus when you come across a slideshow video with synthesized monotonal voice-over which makes the bold claim that somehow medieval iron was superior and today’s metallurgy both worse and designed to break, you really have to do a spit-take. The many corrections in the comment section further reinforces the feeling that it’s more slop than fact.

One of the claims made is that the bloomery furnace beats the blast furnace, due to beneficial additives to the iron. Considering that the video cites its sources, it’s at least worthy of a dive into the actual science here. Are modern iron and steel truly that inferior and disposable?

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CardFlix: NFC Cards For Kid-Friendly Streaming Magic

November 5, 2025 by Matt Varian 7 Comments

For most of us, the days of having to insert a disc to play our media are increasingly behind us. But if you’d like to provide your kids with the experience, you could use CardFlix.

For the electronics, [Udi] used the readily available ESP8266 D1 Mini module connected via I2C to a PN532 NFC reader. To trigger the different movies, there are over 50 cards, each with not only its unique NFC tag but also small posters that [Udi] printed showing the show and then laminated, ensuring they will survive plenty of use. The D1 Mini and NFC reader are housed in a 3D printed case, which ends up being almost smaller than the 5V DC adapter powering it, allowing it to be mounted above an outlet out of the way. The deck of movie cards is also housed in a pair of printed boxes: the larger one for the whole collection and a small one for the most often used shows. Should you want to print your own, all the design files are provided in the write-up.

The D1 Mini was programmed using ESPHome. This firmware allows it to easily connect back to Home Assistant, which does most of the heavy lifting for this project. When a card is scanned, Home Assistant can tell which TV the scanner was near, allowing this system to be used in more than one location. It also knows which card was scanned so it can play the right movie. Home Assistant also handles ensuring the TV in question is powered on, as well as figuring out what service should be called for that particular movie to be shown.

Be sure to check out some of the other projects we’ve featured that use ESPHome to automate tasks.

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