Author: Aaron Beckendorf

140 Articles

A mechanism made of brass and steel is attached to a milling machine. It has a long lever extending from the right side, a counterweight attached to the left side, and an indicator gauge in the middle.

A Precision Drill Press For Tiny Bits

May 16, 2026 by 11 Comments

Anyone who’s worked with even a 1 mm bit knows that while a drill press is all but essential, it isn’t proof against broken bits. Working with a 0.1 mm drill bit seems, therefore, all but impossible, which is why [Mike] of Chronova Engineering built this mechanism to simplify such drilling.

The mechanism is an attachment for a milling machine, and in principle it just needs to move the rotating drill bit up and down. It needs to be extremely precise, though. For context, a good-quality chuck normally has a runout of 30 to 50 microns, which is approaching half the diameter of the drill bit. The mechanism has a collet mounted in the milling machine’s spindle, which transfers rotation to a second spindle. The second spindle is mounted to a runout-compensating drill chuck, and is connected to a lever and counterweight which allow the user to make small, low-force movements. A dial indicator lets the user see how far the bit’s descended.

Most of the parts were machined out of steel or brass, with the handle being made of titanium for lower weight. When the finished device was mounted to the milling machine, the measured runout was severe. After much investigation and reworking, however, the problem turned out to be a damaged collet locating pin, not an issue with the drilling mechanism. As a first test, [Mike] drilled a 0.1 mm hole 1.8 mm deep, then as a challenge drilled six 0.1 mm holes in the end of a thin steel wire. The results weren’t quite as uniform as he wanted, but it took a scanning electron microscope to even see the imperfection.

It won’t help much with very fine drill bits, but if you need a very precisely-placed hole, check out this periscopic drilling camera. If you do break a drill bit in the workpiece, you might be able to dissolve it with alum.

Continue reading “A Precision Drill Press For Tiny Bits” →

A cylindrical grey robot sits on a white mat. The robot is made of three grey sections connected by a series of radially-arranged copper pillars.

Controlling A Vibrobot With Only One Motor

May 14, 2026 by 5 Comments

The vibrobot – a vibrating motor and battery attached to the head of a brush – isn’t truly a robot, since its movement can’t be controlled, but it’s whetted the interest of many future roboticists. With a clever control method, though, it is in fact possible to drive them in any desired direction while using only one motor.

[Namaskar Mitro] based the design of this robot on this research paper; if the vibrating motor is mounted at an angle above the base of the robot, it causes the bot to rotate, and if the motor is mounted off-center from the center of mass, the robot moves in a circle. Crucially, reversing the direction of the motor’s rotation reverses the direction of the robot’s rotation. By rapidly switching the direction of rotation, the bot can move in a series of short, shallow arcs which approximate a straight line.

The robot which [Namaskar] built was based on an ESP-01F microcontroller, which let it be remote-controlled over Wi-Fi. It used a DRF8212 motor driver to control a vibrating pager motor, which was housed inside a 3D-printed enclosure. To move in a straight line, the ESP-01F switches the motor’s direction every 250 milliseconds, which still produces a slightly erratic movement. It can, however, approximately follow a traced path.

This adds to the previous vibrobot control methods we’ve seen: a pair of differentially-driven vibrating motors or a weight-shifting mechanism.

Thanks to [110y6] for the tip!

A web interface is shown providing information about a cellular network base station.

Running Your Own 3G Network

May 9, 2026 by 14 Comments

CDMA2000 was one of the protocols defined for 3G networks and is now years out of date and being phased out worldwide. Nevertheless, there are still vast numbers of phones that will happily connect to it, creating an opportunity for hackers seeking to run their own cellular networks. [Chrismoos] recently made this endeavour significantly easier by releasing 1xBTS, a Rust implementation of the lower three layers of a CDMA2000 network.

The lowest layer of the stack is an SDR for the actual radio communications. It’s been tested with the USRP B200 and B210, the LimeSDR Mini 2, and the BladeRF Micro 2.0. The code might work with certain other SDRs using the SoapySDR abstraction layer. The SDR is controlled by the base station (BTS) software, which, in turn, is controlled by the base station controller (BSC) over an Abis link. The BSC manages channels and mobile device associations, and exchanges frames with the mobile switching center (MSC), which handles message switching.

Continue reading “Running Your Own 3G Network” →

A black and yellow robot dog stands in the middle of the floor, with a GoPro camera mounted on its back. A picture-in-picture view in the bottom left corner shows the view from the camera.

An Improved Robot Dog For Senior Design

May 8, 2026 by 7 Comments

[Aaed Musa] has been building robot dogs for a long time now, so it was only natural that he would make one for the senior design project of his mechanical engineering degree. Since this meant working with potential customers, the requirements were somewhat more stringent than for previous dogs, but [Aaed] and his team were able to deliver CARA 2.0, their most agile, versatile robot yet.

Based on conversations with potential customers, [Aaed] and his team aimed for a price around $1,000 USD, a weight under 20 pounds, and a durable design. Like the original CARA, this used capstan drives to actuate the joints, which reduced costs. The drives were printed in resin and powered by brushless drone motors. These motors were designed for speed, not torque, so the team had to rewind them with more wire, an ordeal which paid off by roughly tripling the torque. As far as durability, one joint motor was tested by running it continuously back and forth, and it lasted for over 1,000 hours without obvious damage.

Since the joints don’t contain any absolute encoders, each motor has to home on startup by extending to its limit, as detected by a rise in motor current. As a happy side effect, this creates a lifelike stretching motion on startup. Compared to the earlier iteration, CARA 2.0 takes shorter, quicker steps, and thanks to angled step movements can turn much more quickly. In testing, it originally skewed to the left, which turned out to be due to an asymmetric leg design. Once corrected, CARA 2.0 could walk in straight lines, walk sideways, turn in place, crouch, jump, and keep its balance on an inclined surface. It didn’t quite make the price goal, but $1,450 is still cheap for such a capable robot dog, and it reached every other customer requirement. Most importantly, all the team graduated.

For another take on a capstan-powered robot dog, check out Stanley. We’ve also taken a look at TOPS, one of [Aaed]’s earlier designs.

Continue reading “An Improved Robot Dog For Senior Design” →

A fine steel gear is shown held between a man's fingertips.

Cutting Steel Gears With Homemade EDM

May 5, 2026 by 17 Comments

Electric discharge machining (EDM) may be slower than alternatives like laser cutting, water jets, or a milling machine, but for some applications there’s no alternative: it can cut through any conductive material, no matter how hard, and it leaves no mechanical or thermal stress in the workpiece. Best of all, they’re relatively accessible for a resourceful hacker, such as [Inofid], who recently built the second iteration of his desktop wire EDM.

The EDM’s motion system comes from a cheap desktop CNC router, which had a water tank mounted in its workspace and had the spindle replaced with a wire-management mechanism. The wire-management mechanism needs to continuously wind a tensioned brass wire from one spool through the cutting zone onto another spool. The tensioning system uses two motors: one to pull the wire through, and one to maintain tension by slightly counteracting it, with a tension sensor and Ardunio to maintain the proper tension. If it detects that the wire has broken, it can stop the CNC controller. To keep the wire from breaking or short-circuiting with the workpiece, a current monitor counts sparks between the wire and workpiece and uses this to predict whether the wire is getting too close to the metal, in which case it slows down the movement.

As a first test, [Inofid] cut through a five by three centimeters-thick block of aluminium, taking two hours but producing a clean cut. To speed up the next cut, [Inofid] added a pump and filter to remove sludge from the cutting area. The next cut was an aluminium gear, and then a meshing steel gear, which took about ten hours but turned out well.

EDMs of various kinds appear here from time to time, particularly since the popularization of 3D printers. We’ve even seen one built into a lathe.

Thanks to [Keith Olson] for the tip!

A red box with a yellow front panel is shown. The front panel contains a power switch, an indicator light, and a small OLED display.

A Shortwave Sensor To Monitor The Ionosphere

May 4, 2026 by 9 Comments

The ionosphere is of great importance to shortwave radio transmissions, since it allows radio waves to be refracted and reflected over the horizon, and it’s therefore unfortunate that the height and thickness of the ionosphere depends on the time of day or night, weather, season, and the solar cycle. To get a better idea of current transmission conditions, [mircemk] built this shortwave propagation monitor.

The monitor provides a basic measure of ionosphere conditions by measuring the strength of received shortwave signals: if the conditions for transmission are good, it should receive a relatively high level of existing signals, and a weak signal if conditions are bad. It has an external antenna connected to a signal strength indicator circuit based on the CA3089, which amplifies signals in the 1-40 MHz range and outputs a smoothed voltage indicating the RF energy in this range. The output signal can be read by any voltmeter, in this case an Arduino Nano with an OLED display. Assuming the same antenna is always used, the signal should noticeably fluctuate between night and day as the solar wind affects the ionosphere.

Of course, the distance at which you’ll be receiving a signal means nothing unless you have a receiver, which can range from the antique to the modern.

A man's hand is shown holding a color photograph of a vase of flowers against a black background.

True-Spectrum Photography With Structural Color

May 3, 2026 by 34 Comments

Although modern cameras can, with skill and good conditions, produce photographs nearly indistinguishable from the original scene, this fidelity relies on the limitations of human vision. According to the trichromatic theory, humans perceive light as a mixture of three colors, which can be recorded and represented by cameras, displays, and color printing; a spectrometer, however, can detect a clear distance between the three colors present in a photograph and the wide range of spectra in the original scene. By contrast, one of the earliest color photography methods, Lippmann plates, captured not just true color, but true spectra.

A Lippmann plate, as [Jon Hilty] details, starts with a layer of photographic gel containing extremely fine silver halide crystals over the back of a glass plate. This layer is placed on top of a mirror, traditionally a mercury bath, and put in the camera. When light passes through the emulsion and reflects off the mirror, it interferes with incoming light to create a standing wave. The portions of the emulsion at the wave’s antinodes absorb the most energy, converting local silver halide crystals into reflective silver. The spacing of the silver particles depends on the incoming light’s wavelength, and is fixed in place during the development process.

This creates a matrix of vertically-stacked diffraction gratings, each diffracting back the original wavelength when illuminated with white light. Unlike normal diffraction gratings, the wavelength of diffracted light doesn’t depend strongly on the viewing angle; since the interference structure here is vertically-arranged, it refracts a narrow range of wavelengths across all possible viewing angles. The viewing angles, however, are limited; unlike with dye-based photographs, you can only view the colors nearly straight-on. This, along with the necessity for long exposures, the chance of producing washed-out colors, and the impossibility of creating reprints, kept Lippmann plates from ever really catching on. The basic concept lives on in holograms, which encode spatial information in a similar kind of photographically-formed diffraction pattern.

For a more conventional method of color photography, we’ve also seen a recreation of the autochrome method. Alternatively, check out this homemade silver halide photography emulsion.

Thanks to [Stephen Walters] for the tip!