A magnifying glass is seen behind a small tea candle. The magnifying image is projecting the shadow of a column of heated air.

Finding Simpler Schlieren Imaging Systems

October 6, 2025 by Aaron Beckendorf 3 Comments

Perhaps the most surprising thing about shadowgraphs is how simple they are: you simply take a point source of light, pass the light through a the volume of air to be imaged, and record the pattern projected on a screen; as light passes through the transition between areas with different refractive indices, it gets bent in a different direction, creating shadows on the viewing screen. [Degree of Freedom] started with these simple shadowgraphs, moved on to the more advanced schlieren photography, and eventually came up with a technique sensitive enough to register the body heat from his hand.

The most basic component in a shadowgraph is a point light source, such as the sun, which in experiments was enough to project the image of an escaping stream of butane onto a sheet of white paper. Better point sources make the imaging work over a wider range of distances from the source and projection screen, and a magnifying lens makes the image brighter and sharper, but smaller. To move from shadowgraphy to schlieren imaging, [Degree of Freedom] positioned a razor blade in the focal plane of the magnifying lens, so that it cut off light refracted by air disturbances, making their shadows darker. Interestingly, if the light source is small and point-like enough, adding the razor blade makes almost no difference in contrast.

With this basic setup under his belt, [Degree of Freedom] moved on to more unique schlieren setups. One of these replaced the magnifying lens with a standard camera lens in which the aperture diaphragm replaced the razor blade, and another replaced the light source and razor with a high-contrast black-and-white pattern on a screen. The most sensitive technique was what he called double-pinhole schlieren photography, which used a pinhole for the light source and another pinhole in place of the razor blade. This could image the heated air rising from his hand, even at room temperature.

The high-contrast background imaging system is reminiscent of this technique, which uses a camera and a known background to compute schlieren images. If you’re interested in a more detailed look, we’ve covered schlieren photography in depth before.

Thanks to [kooshi] for the tip!

A person's hand wearing a black glove is shown in the right part of the image, making a series of gestures. A representation of a hand mimics those motions on a laptop screen.

Weaving Circuits From Electronic Threads

October 6, 2025 by Aaron Beckendorf 6 Comments

Though threading is a old concept in computer science, and fabric computing has been a term for about thirty years, the terminology has so far been more metaphorical than strictly descriptive. [Cedric Honnet]’s FiberCircuits project, on the other hand, takes a much more literal to weaving technology “into the fabric of everyday life,” to borrow the phrase from [Mark Weiser]’s vision of computing which inspired this project. [Cedric] realized that some microcontrollers are small enough to fit into fibers no thicker than a strand of yarn, and used them to design these open-source threads of electronics (open-access paper).

The physical design of the FiberCircuits was inspired by LED filaments: a flexible PCB wrapped in a protective silicone coating, optionally with a protective layer of braiding surrounding it. There are two kinds of fiber: the main fiber and display fibers. The main fiber (1.5 mm wide) holds an STM32 microcontroller, a magnetometer, an accelerometer, and a GPIO pin to interface with external sensors or other fibers. The display fibers are thinner at only one millimeter, and hold an array of addressable LEDs. In testing, the fibers could withstand six Newtons of force and be bent ten thousand times without damage; fibers protected by braiding even survived 40 cycles in a washing machine without any damage. [Cedrik] notes that finding a PCB manufacturer that will make the thin traces required for this circuit board is a bit difficult, but if you’d like to give it a try, the design files are on GitHub.

[Cedrik] also showed off a few interesting applications of the thread, including a cyclist’s beanie with automatic integrated turn signals, a woven fitness tracker, and a glove that senses the wearer’s hand position; we’re sure the community can find many more uses. The fibers could be embroidered onto clothing, or embedded into woven or knitted fabrics. On the programming side, [Cedrik] ported support for this specific STM32 core to the Arduino ecosystem, and it’s now maintained upstream by the STM32duino project, which should make integration (metaphorically) seamless.

One area for future improvement is in power, which is currently supplied by small lithium batteries; it would be interesting to see an integration of this with power over skin. This might be a bit more robust, but it isn’t first knitted piece of electronics we’ve seen. Of course, rather than making wearables more unobtrusive, you can go in the opposite direction. Continue reading “Weaving Circuits From Electronic Threads” →

A man is shown behind a table, on which a glass apparatus like a distillation apparatus is set, with outlets leading into a large container in the center of the table, and from there to a pump.

Pulling A High Vacuum With Boiling Mercury

October 3, 2025 by Aaron Beckendorf 21 Comments

If you need to create a high vacuum, there are basically two options: turbomolecular pumps and diffusion pumps. Turbomolecular pumps require rotors spinning at many thousands of rotations per minute and must be carefully balanced to avoid a violent self-disassembly, but diffusion pumps aren’t without danger either, particularly if, like [Advanced Tinkering], you use mercury as your working fluid. Between the high vacuum, boiling mercury, and the previous two being contained in fragile glassware, this is a project that takes steady nerves to attempt – and could considerably unsteady those nerves if something were to go wrong.

Continue reading “Pulling A High Vacuum With Boiling Mercury” →

A violet laser beam is shown expanding outward from a diode in a darkened room and illuminating the back of a man's hand.

Driving A Laser At 200 Volts For Nanoseconds

September 30, 2025 by Aaron Beckendorf 26 Comments

If there’s one lesson to be learned from [Aled Cuda]’s pulsed laser driver, it’s that you can treat the current limits on electronic components as a suggestion if the current duration is measured in nanoseconds.

The components in question are a laser diode and an NPN transistor, the latter of which operates in avalanche mode to drive nanosecond-range pulses of high current through the former. A buck-boost converter brings a 12 volt power supply up to 200 volts, which then passes through a diode and into the avalanche transistor, which is triggered by an external pulse generator. On the other side of the transistor is a pulse-shaping network of resistors and capacitors, the laser diode, and a parallel array of low-value resistors, which provide a current monitor by measuring the voltage across them. There is an optoisolator to protect the pulse generator from the 200 volt lines on the circuit board, but for simplicity’s sake it was omitted from this iteration; there is some slight irony in designing your own laser driver for the sake of the budget, then controlling it with “a pulse generator we don’t mind blowing up.” We can only assume that [Aled] was confident in his work.

The video below details the assembly of the circuit board, which features some interesting details, such as the use of a transparent solder mask which makes the circuit layout clear while still helping to align components during reflow. The circuit did eventually drive the diode without destroying anything, even though the pulses were probably 30 to 40 watts. A pulse frequency of 360 hertz gave a nice visual beating effect due to small mismatches between the pulse frequency of the driver and the frame rate of the camera.

This isn’t the first laser driver to use avalanche breakdown for short, high-power pulses, but it’s always good to see new implementations. If you’re interested in further high-speed electronics, we’ve covered them in more detail before.

Continue reading “Driving A Laser At 200 Volts For Nanoseconds” →

Two pieces of metal are sitting next to each other on a brick, with one edge touching. The copper end of a torch is directing a flame against the metal, and the metal is glowing brightly around the point where the flame contacts it.

Welding With Natural Gas And Oxygen

September 21, 2025 by Aaron Beckendorf 15 Comments

By virtue of its triple bond, acetylene burns hotter than any other common hydrocarbon when mixed with oxygen, but it isn’t the only flame hot enough for welding. With the assistance of a homemade oxygen concentrator, [Hyperspace Pirate] was able to make a natural gas torch that melts steel, even if welding with the torch remains difficult.

[Hyperspace Pirate] built his oxygen concentrator around a pressure-swing adsorption system, which uses two tanks of a molecular sieve to selectively adsorb and purge nitrogen, leaving behind mostly oxygen. [Hyperspace Pirate] used reverse-osmosis membrane casings as the tanks, solenoid valves to control gas flow, and an Arduino with some MOSFETs to control the timing. For fuel, he used a convenient source of natural gas, already installed in his garage: the water heater’s gas supply. Since the house’s meter regulates the gas down to a fairly low pressure, and the oxygen concentrator doesn’t produce high pressures, the torch didn’t need any inline regulators.

Inline check valves, on the other hand, were very much necessary, a mixture of oxygen and natural gas propagating back along the lines being undesirable for obvious reasons, and flashback arrestors would have been a good addition. [Hyperspace Pirate] built the torch itself out of copper tubing and needle valves, with a 0.9 mm MIG welder tip as the nozzle. Adjusting the gas mixture was mostly a matter of trial and error. With an oxygen-rich flame, it could cut thin metal decently well, but it tended to melt thick pieces more than it cut. On the other hand, even with a neutral flame, the water vapor in the exhaust oxidized steel, which made welding quite difficult, but not impossible.

The oxygen supply by itself was an entertaining tool, turning smoldering pieces of charcoal or steel wool violently incandescent. With the assistance of some steel wool, [Hyperspace Pirate] set a steel tube on fire. With a bit more oxygen, it would probably make an effective thermic lance. If you still want to do your welding with acetylene, he’s also made that before.

Continue reading “Welding With Natural Gas And Oxygen” →

A black, rectangular box is shown, with a number of waterproof screw connectors on the front.

A Ruggedized Raspberry Pi For Sailors

September 20, 2025 by Aaron Beckendorf 33 Comments

Nautical navigation has a long history of innovation, from the compass and chronometer to today’s computer-driven autopilot systems. That said, the poor compatibility of electronics with saltwater has consequently created a need for rugged, waterproof computers, a category to which [Matti Airas] of Hat Labs has contributed with the open-source HALPI2.

Powered by the Raspberry Pi Compute Module 5, the electronics are housed in a heavy duty enclosure made of aluminium, which also serves as a heat sink, and closes with a waterproof seal. It has a wide variety of external connectors, all likewise waterproofed: power, HDMI, NMEA 2000 and NMEA 0183, Ethernet, two USB 3.0 ports, and an external WiFi or Bluetooth antenna. The external ports are plugged into the carrier board by short extension cables, and there are even more ports on the carrier board, including two HDMI connectors, two MIPI connectors, four USB ports, and a full GPIO header. The case has plugs to install additional PG7 or SP13 waterproof connectors, so if the existing external connectors aren’t enough, you can add your own.

Besides physical ruggedness, the design is also resistant to electrical damage. It can run on power in the 10-32 volt range, and is protected by a fuse. A supercapacitor bank preserves operation during a power glitch, and if the outage lasts for more than five seconds, can keep the system powered for 30-60 seconds while the operating system shuts down safely. The HALPI2 can also accept power over NMEA 2000, in which case it has the option to limit current draw to 0.9 amps.

The design was originally created to handle navigation, data logging, and other boating tasks, so it’s been configured for and tested with OpenPlotter. Its potential uses are broader than that, however, and it’s also been tested with Raspberry Pi OS for more general projects. Reading through its website, the most striking thing is how thoroughly this is documented: the site describes everything from the LED status indicators to the screws that close the housing – even a template for drilling mounting holes.

Given the quality of this project, it probably won’t surprise you to hear this isn’t [Matti]’s first piece of nautical electronics, having previously made Sailor HATs for the ESP32 and the Raspberry Pi.

A lathe is shown on a tabletop. Instead of a normal lathe workspace, there is an XY positioning platform in front of the chuck, with two toolposts mounted on the platform. Stepper motors are mounted on the platform to drive it. The lathe has no tailpiece.

Turning A Milling Machine Into A Lathe

September 13, 2025 by Aaron Beckendorf 8 Comments

If you’re planning to make a metalworking lathe out of a CNC milling machine, you probably don’t expect getting a position sensor to work to be your biggest challenge. Nevertheless, this was [Anthony Zhang]’s experience. Admittedly, the milling machine’s manufacturer sells a conversion kit, which greatly simplifies the more obviously difficult steps, but getting it to cut threads automatically took a few hacks.

The conversion started with a secondhand Taig MicroMill 2019DSL CNC mill, which was well-priced enough to be purchased specifically for conversion into a lathe. Taig’s conversion kit includes the spindle, tool posts, mounting hardware, and other necessary parts, and the modifications were simple enough to take only a few hours of disassembly and reassembly. The final lathe reuses the motors and control electronics from the CNC, and the milling motor drives the spindle through a set of pulleys. The Y-axis assembly isn’t used, but the X- and Z-axes hold the tool post in front of the spindle.

The biggest difficulty was in getting the spindle indexing sensor working, which was essential for cutting accurate threads. [Anthony] started with Taig’s sensor, but there was no guarantee that it would work with the mill’s motor controller, since it was designed for a lathe controller. Rather than plug it in and hope it worked, he ended up disassembling both the sensor and the controller to reverse-engineer the wiring.

He found that it was an inductive sensor which detected a steel insert in the spindle’s pulley, and that a slight modification to the controller would let the two work together. In the end, however, he decided against using it, since it would have taken up the controller’s entire I/O port. Instead, [Anthony] wired his own I/O connector, which interfaces with a commercial inductive sensor and the end-limit switches. A side benefit was that the new indexing sensor’s mounting didn’t block moving the pulley’s drive belt, as the original had.

The end result was a small, versatile CNC lathe with enough accuracy to cut useful threads with some care. If you aren’t lucky enough to get a Taig to convert, there are quite a few people who’ve built their own CNC lathes, ranging from relatively simple to the extremely advanced.