Author: Aaron Beckendorf

136 Articles

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

Cutting Steel Gears With Homemade EDM

May 5, 2026 by 15 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 28 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!

An ultrasonic transducer with two wires attached to it by alligator clips floats very slightly suspended over a glass surface.

A Different Kind Of Ultrasonic Levitation

April 27, 2026 by 3 Comments

Ultrasonic levitation is by now a familiar trick: one or more ultrasonic transducers create a standing wave, and small objects can be held in the nodes of this standing wave. With a sufficiently large array of transducers, it’s even possible to control the movement of the object. This isn’t the only form of ultrasonic levitation, however, as [Steve Mould] demonstrated with his ultrasonic air hockey table.

This less familiar form of levitation was discovered by [Bob Collins] while working on torpedo guidance systems: when he tried to place a glass lens on an ultrasonic transducer it immediately slid off. He found during further experimentation that an ultrasonic transducer would levitate over any sufficiently flat and smooth surface. It works by trapping a very thin layer of air between the transducer and the smooth surface. When the transducer moves sharply toward the surface, it compresses a layer of air in between, and forces some air out, and the reverse happens while pulling back. However, during the downstroke, the gap through which air can escape is narrower than during the upstroke, and there is more surface-induced drag, meaning that the inflow and outflow of air through a narrow gap isn’t completely equal. At a certain distance, inflow and outflow balance, and the transducer floats on a thin layer of air. Continue reading “A Different Kind Of Ultrasonic Levitation” →

A drill bit, not apparently rotating, descends toward a block of aluminium and throws up aluminium shavings as it passes through the block.

Freeze Moving Tools With A Stroboscopic Camera

April 26, 2026 by 20 Comments

If you take a video of a spinning wheel, you’ll probably notice that the spokes appear to turn more slowly than the wheel is actually rotating, and sometimes in the wrong direction. This is caused by a near match in the frame rate of the camera and the rate of rotation of the wheel – each time the camera captures a frame, the wheel has rotated a spoke into nearly the same position as in the last frame. If you time the exposures carefully, as [Excessive Overkill] did in his latest video, this effect can seemingly freeze moving objects, such as a fan or saw blade.

Most cameras only allow relatively coarse, fixed adjustments to frame rate, making it difficult to synchronize the shutter to an object’s motion. To get around this, [Excessive Overkill] used an industrial camera (previously used in this aimbot), which has fine frame rate control and external triggering. He connected the external trigger to a laser sensor, which detects a piece of retroreflective tape every time it passes by (for example, on one blade of a fan). When the laser sensor sends a signal, it also triggers a powerful LED flash. The flash is so powerful that dark materials create a hum when exposed to it, as pulses quickly heat the material, but each pulse is also so brief that the flash board doesn’t require any cooling.

Continue reading “Freeze Moving Tools With A Stroboscopic Camera” →

A hexagonal brass enclosure surrounds an aluminium fan with three blades. The fan has an integrated outer rim with a series of small holes around the rim.

Building A Rim-Driven Jet Engine

April 19, 2026 by 18 Comments

Rim-driven thrusters turn the normal propeller-motor arrangement inside out; rather than mounting the motor at the center of the propeller, they use a large hollow motor, with the blades attached to the inside of the rotor. They’re mostly used in ship propellers, though there have been some suggestions to use them in electric aircraft. [Integza], always looking for new and unusual ways to create propulsion, took this idea and made it into a jet engine.

Rather than using an electric motor, the fan in this design is propelled by miniature rocket nozzles along the edge. The fan levitates on a layer of high-pressure gas between the fan rim and the housing. To prevent too much pressurized gas from escaping, the fan and housing needed to fit together closely, but with minimal friction. A prototype made out of acrylic and resin and powered by compressed air proved that the idea worked, but [Integza] wanted to make to this a combustion-powered engine.

Continue reading “Building A Rim-Driven Jet Engine” →

A man's hand is holding a thin wooden board, which runs between two vertical metal plates. On the board are two glasses, one filled with water. A computer screen is behind all this, showing a series of white bars. The series of bars shows two peaks.

Using Capacitance For Extremely Sensitive Proximity Sensing

April 18, 2026 by 18 Comments

Capacitive displacement sensors span a wide range of resolution, from the touchscreen sensors which can only detect displacement as a binary state, all the way to the sensors in semiconductor fabs which measure down to nanometers. The sensor [Matthias Wandel] built with a Raspberry Pi Pico lands somewhere in the middle, providing both sensitive measurements and an absolute scale.

The idea is that the amount of overlap between two metal plates should be detectable by measuring the capacitance between them. Reaching any kind of usable resolution would require a very precise measure of capacitance, around the picofarad range. [Matthias] realized that the Pico’s GPIO pins have an inherent capacitance, and can have a pull-down resistor set, essentially creating an RC circuit. [Matthias] would set a pin to a high-level output, then switch it to an input. The amount of time the pin takes to switch from high to low indicates the RC constant, which includes the capacitance attached to the pin.

When attached to a metal plate, the Pico was sensitive enough to detect the plate’s capacitive coupling to [Matthias]’s hand through a thick wooden floor. To measure capacitance between two metal plates, the Pico measured how well a voltage signal applied to one plate was coupled to the other plate. This was sensitive enough to measure the slight change in the dielectric constant when [Matthias] waved a piece of ABS pipe between the two capacitor plates. Making actual position measurements was tricky, since capacitance changed with both X- and Z-axis shifts in the plates.

Digital calipers use similar capacitive sensors to make their measurements, as [Matthias] knows from his experiments in hacking them. If you’re interested in more details, check out this teardown of some cheap digital calipers.

Continue reading “Using Capacitance For Extremely Sensitive Proximity Sensing” →