Author: Aaron Beckendorf

110 Articles

A small piece of brown plastic is held in two pairs of tweezers under a heat gun, and is being twisted.

A New And Strangely Strong Kind Of Plastic

February 9, 2026 by 7 Comments

As anyone who extrudes plastic noodles knows, the glass transition temperature of a material is a bit misleading; polymers gradually transition between a glass and a liquid across a range of temperatures, and calling any particular point in that range the glass transition temperature is a bit arbitrary. As a general rule, the shorter the glass transition range is, the weaker it is in the glassy state, and vice-versa. A surprising demonstration of this is provided by compleximers, a class of polymers recently discovered by researchers from Wageningen University, and the first organic polymers known to form strong ionic glasses (open-access article).

When a material transforms from a glass — a hard, non-ordered solid — to a liquid, it goes through various relaxation processes. Alpha relaxations are molecular rearrangements, and are the main relaxation process involved in melting. The progress of alpha relaxation can be described by the Kohlrausch-Williams-Watts equation, which can be exponential or non-exponential. The closer the formula for a given material is to being exponential, the more uniformly its molecules relax, which leads to a gradual glass transition and a strong glass. In this case, however, the ionic compleximers were highly non-exponential, but nevertheless had long transition ranges and formed strong glasses.

The compleximers themselves are based on acrylate and methacrylate backbones modified with ionic groups. To prevent water from infiltrating the structure and altering its properties, it was also modified with hydrophobic groups. The final glass was solvent-resistant and easy to process, with a glass transition range of more than 60 °C, but was still strong at room temperature. As the researchers demonstrated, it can be softened with a hot air gun and reshaped, after which it cools into a hard, non-malleable solid.

The authors note that these are the first known organic molecules to form strong glasses stabilized by ionic interactions, and it’s still not clear what uses there may be for such materials, though they hope that compleximers could be used to make more easily-repairable objects. The interesting glass-transition process of compleximers makes us wonder whether their material aging may be reversible.

A cuboctahedron (a kind of polyhedron) made out of LED filaments is being held above a man's hand in front a computer screen.

The Graph Theory Of Circuit Sculptures

February 3, 2026 by 6 Comments

Like many of us, [Tim]’s seen online videos of circuit sculptures containing illuminated LED filaments. Unlike most of us, however, he went a step further by using graph theory to design glowing structures made entirely of filaments.

The problem isn’t as straightforward as it might first appear: all the segments need to be illuminated, there should be as few powered junctions as possible, and to allow a single power supply voltage, all paths between powered junctions should have the same length. Ideally, all filaments would carry the same amount of current, but even if they don’t, the difference in brightness isn’t always noticeable. [Tim] found three ways to power these structures: direct current between fixed points, current supplied between alternating points so as to take different paths through the structure, and alternating current supplied between two fixed points (essentially, a glowing full-bridge rectifier).

To find workable structures, [Tim] represented circuits as directed graphs, with each junction being a vertex and each filament a directed edge, then developed filter criteria to find graphs corresponding to working circuits. In the case of power supplied from fixed points, the problem turned out to be equivalent to the edge-geodesic cover problem. Graphs that solve this problem are bipartite, which provided an effective filter criterion. The solutions this method found often had uneven brightness, so he also screened for circuits that could be decomposed into a set of paths that visit each edge exactly once – ensuring that each filament would receive the same current. He also found a set of conditions to identify circuits using rectifier-type alternating current driving, which you can see on the webpage he created to visualize the different possible structures.

We’ve seen some artistic illuminated circuit art before, some using LED filaments. This project doesn’t take exactly the same approach, but if you’re interested in more about graph theory and route planning, check out this article.

A set of three stacked oscilloscopes is shown. The lower two oscilloscopes have screens and input pins visible, and the top oscilloscope is reversed, with a printed back plate visible.

A Higher-End Pico-Based Oscilloscope

February 2, 2026 by 29 Comments

Hackers have been building their own basic oscilloscopes out of inexpensive MCUs and cheap LCD screens for some years now, but microcontrollers have recently become fast enough to actually make such ‘scopes useful. [NJJ], for example, used a pair of Raspberry Pi Picos to build Picotronix, an extensible combined oscilloscope and logic analyzer.

This isn’t an open-source project, but it is quite well-documented, and the general design logic and workings of the device are freely available. The main board holds two Picos, one for data sampling and one to handle control, display, and external communication. The control unit is made out of stacked PCBs surrounded by a 3D-printed housing; the pinout diagrams printed on the back panel are a helpful touch. One interesting technique was to use a trimmed length of clear 3D printer filament as a light pipe for an indicator LED.

Even the protocol used to communicate between the Picos is documented; the datagrams are rather reminiscent of Ethernet frames, and can originate either from one of the Picos or from a host computer. This lets the control board operate as an automatic testing station reporting data over a wireless or USB-connected network. The display module is therefore optional hardware, and a variety of other boards (called picoPods) can be connected to the Picotronix control board. These include a faster ADC, adapters for various analog input spans, a differential analog input probe, a 12-bit logic state analyzer, and a DAC for signal generation.

If this project inspired you to make your own, we’ve also seen other Pico-based oscilloscopes before, including one that used a phone for the display.

A small plastic object can be seen in front of the tip of a hypodermic needle. The object is made of clear, slightly purple-tinted plastic. It is roughly circular, with edges thicker than the center.

The Latest From RepRapMicron – Nail Gel, First Objects, And More

February 1, 2026 by 12 Comments

We’ve been following [Vik Olliver]’s progress on the μRepRap project with interest for some time now. The project’s goal is to build a 3D printer that can print feature sizes down to about 10 microns – the same feature size used in the Intel 4004 processor. At the recent Everything Open 2026 conference, [Vik] presented an overview of all the progress he’s made in the last year, including printer improvements, material woes, and the first multi-layer prints (presentation slides).

The motion stage has undergone some fundamental improvements recently. The original XY motion table was supported on four flexures which allowed movement in X and Y, but also introduced slight variations in Z – obviously a problem in a system that needs to be accurate down to the microns. The latest version now uses complementary flexures to maintain a constant Z height, and eliminates interference between the X and Y axes. The axis motion drivers were also redesigned with parallel-bar linear reducers inspired by a pantograph, increasing their usable range from two to eight millimeters.

Rather than extruding material, the μRepRap uses an electrochemically-etched needle point to deposit UV-curable gel on the build surface. [Vik] found that a bit of nitric acid in the needle etching solution gave the edges of the probe a bit of a rough texture which let it hold more resin. He started his test prints using normal 3D printer resin, but it turns out that dissolved oxygen inhibits curing – quite a problem for small, air-exposed droplets. Fortuitously, UV nail gel does cure in air, and the next set of tests were printed in nail gel, including the first layered prints (one of which can be seen above, on top of a hypodermic needle). The μRepRap can’t yet print large numbers of layers, but [Vik] did print some hinged parts that could be folded into shape.

There’s much more in the presentation than can be covered here, including some interesting thoughts about the possibility of 3D printing electrochemical memory cells in ionic gel. Near the end of the presentation, [Vik] listed some pieces of related work, including necroprinting and this homemade micro-manipulator.

 

Building A Metal 3D Printer With A Laser Welder

February 1, 2026 by 6 Comments

The development of cheaper, more powerful lasers has always been a cause for excitement among hackers, and fiber lasers are no exception. One of the newer tools they’ve enabled is the laser welder, which can be used to weld, cut through metal, or clean off surfaces. Or, as [Cranktown City] demonstrated, you can use one to build a metal 3D printer.

The printer’s built around a 2000-Watt fiber laser welder from Skyfire, and the motion system came from a defunct secondhand 3D printer built by an out-of-business insole printing company. The frame was reinforced with steel, the welding gun was mounted in place of the hotend, and the trigger was replaced with a CNC-controlled switch. It didn’t originally use any specific shielding gas, since the welder was supposed to perform adequately with just compressed air if high weld quality wasn’t essential.

The first few tests were promising, but did reveal quite a few problems. Heat buildup was an early issue which threatened to warp the build plate, and which eventually welded the build plate to the Z-axis gantry. Adding a strong cooling fan and putting a gap between the build plate and the gantry solved this. The wire also kept getting stuck to the build surface, which [Cranktown City] solved by pausing the wire feed and pulling it away from the part when a layer finished. Simply using compressed air led to a weak deposit that cracked easily, and while a nitrogen stream improved the print somewhat, argon shielding gas gave the best results. For his final print, [Cranktown City] made a vase. The layers were a bit crude, but better than most welder-based metal printers, and the system shows some real promise.

We’ve seen a few printers built around welders before, and a few built around lasers, but this seems to be the first to use both.

A wooden frame is shown with a scale pulling down on a 3D-printed part held in the frame. A phone on a stand is taking video of the part.

Changing Print Layer Patterns To Increase Strength

January 31, 2026 by 2 Comments

Dy default, the slicing software used for 3D printers has the printer first create the walls around the edges of a print, then goes back to deposit the infill pattern. [NeedItMakeIt], however, experimented with a different approach to line placement, and found significant strength improvements for some filaments.

The problem, as [NeedItMakeIt] identified with a thermal camera, is that laying down walls around a print gives the extruded plastic time to cool of. This means new plastic is being deposited onto an already-cooled surface, which reduces bonding strength. Instead, he used an aligned rectilinear fill pattern to print the solid parts. In this pattern, the printer is usually extruding filament right next to the filament it just deposited, which is still hot and therefore adheres better. The extrusion pattern is also aligned vertically, which might improve inter-layer bonding at the transition point.

To try it out, he printed a lever-type test piece, then recorded the amount of force it took to break a column free from the base. He tried it with a default fill pattern, aligned fill, and aligned fill with a single wall around the outside, and printed copies in PLA, plain PETG, and carbon fiber-reinforced PETG. He found that aligned fill improved strength in PLA and carbon fiber PETG, in both cases by about 46%, but led to worse performance in plain PETG. Strangely, the aligned fill with a single outside wall performed better than default for PLA, but worse than default in both forms of PETG. The takeaway seems to be that aligned fill improves layer adhesion when it’s lacking, but when adhesion is already good, as with PETG, it’s a weaker pattern overall.

Interesting, [MakeItPrintIt]’s test results fit in well with previous testing that found carbon fiber makes prints weaker. Another way to get stronger print fill patterns is with brick layers.

Continue reading “Changing Print Layer Patterns To Increase Strength” →

Two very similar diffraction patterns are shown, in patterns of green dots against a blue background. The left image is labelled "Kompressions-algorithmus", and the one on the right is labelled "Licht & Zweibelzellen".

Why Diffraction Gratings Create Fourier Transforms

January 27, 2026 by 9 Comments

When last we saw [xoreaxeax], he had built a lens-less optical microscope that deduced the structure of a sample by recording the diffraction patterns formed by shining a laser beam through it. At the time, he noted that the diffraction pattern was a frequency decomposition of the specimen’s features – in other terms, a Fourier transform. Now, he’s back with an explanation of why this is, deriving equations for the Fourier transform from the first principles of diffraction (German video, but with auto-translated English subtitles. Beware: what should be “Huygens principle” is variously translated as “squirrel principle,” “principle of hearing,” and “principle of the horn”).

The first assumption was that light is a wave that can be adequately represented by a sinusoidal function. For the sake of simplicity (you’ll have to take our word for this), the formula for a sine wave was converted to a complex number in exponential form. According to the Huygens principle, when light emerges from a point in the sample, it spreads out in spherical waves, and the wave at a given point can therefore be calculated simply as a function of distance. The principle of superposition means that whenever two waves pass through the same point, the amplitude at that point is the sum of the two. Extending this summation to all the various light sources emerging from the sample resulted in an infinite integral, which simplified to a particular form of the Fourier transform.

One surprising consequence of the relation is the JPEG representation of a micrograph of some onion cells. JPEG compression calculates the Fourier transform of an image and stores it as a series of sine-wave striped patterns. If one arranges tiles of these striped patterns according to stripe frequency and orientation, then shades each tile according to that pattern’s contribution to the final image, one gets a speckle pattern with a bright point in the center. This closely resembles the diffraction pattern created by shining a laser through those onion cells.

For the original experiment that generated these patterns, check out [xoreaxeax]’s original ptychographical microscope. Going in the opposite direction, researchers have also used physical structures to calculate Fourier transforms.

Continue reading “Why Diffraction Gratings Create Fourier Transforms” →