Author: Aaron Beckendorf

148 Articles

A 3D printer hotend with four filament leads in positioned on an arm above a hole in a glass plate. Wires lead from a carbon fiber frame under the glass to four stepper motors with pulleys.

The Final Steps To A Sub-Minute Benchy

May 30, 2026 by 9 Comments

In 2024, [Jan Roetz] decided to see whether he could 3D print a Benchy – the boat-shaped benchmarking tool used in 3D printer calibration – in less than one minute. Two years later, after experiments with air bearing print beds, dry ice cooling, multi-filament hotends, and more, he’s finally broken the one-minute mark.

There are three primary factors limiting the speed of the printer: the extrusion flow rate, the cooling rate for extruded plastic, and the motion system itself. The printer’s hotend combines four strands of filament in one hotend and can extrude about 400 cubic millimeters of plastic per second. For cooling, an air duct around the nozzle could deliver about 400 liters of air per minute, which left the motion system as the only bottleneck.

The original print bed was on top of an air bearing on a granite base, and its motion could be controlled by cords connected to stepper motors. This whole system had very low friction, but its inertia was too high. [Jan] therefore replaced the build plate with a lighter carbon-fiber frame. This had no air bearing, but it slid between the base granite slab and a glass plate above it, which had an opening above the portion used as a build plate. Even the metal pulleys used on the stepper motors had too much inertia, so [Jan] replaced them with smaller, semi-circular plastic pulleys.

The first test was a sub-60-second dry run to make sure nothing would break. This revealed the need for cable guides to keep them from whipping around (not surprising when they were pulling the bed at an acceleration of 225 G). Finally, [Jan] was able to successfully print several successive 59-second Benchies. The prints weren’t photogenic, but they were mechanically sound and dimensionally correct. [Jan] could have gone even faster, but this degraded the print quality too much.

It’s quite an accomplishment, and an impressive conclusion to a major project; we covered the beginning of the project back when [Jan] was going for parallelization rather than speed. The final print didn’t use it, but he also experimented with dynamic temperature control.

Continue reading “The Final Steps To A Sub-Minute Benchy” →

A person is standing in front of an acrylic enclosure, lowering a door on the enclosure. The enclosure contains the space between two sets of cabinets, and has three doors on the front. Inside the enclosure is an air filter and a washing station.

A Fume-Control Cabinet For Resin 3D Printing

May 29, 2026 by 6 Comments

For a certain kind of intricate, highly-detailed manufacturing, there’s really no substitute for a resin 3D printer, and it’s therefore unfortunate that they require so many poisonous chemicals. The resin itself usually contains irritating acrylates and methacrylates, it can emit a wide spectrum of volatile organic compounds (VOCs) during printing, and even the isopropyl alcohol used in cleaning is moderately toxic. [Allie Katz] accordingly built this fume-control enclosure for resin printing and other ventilation-critical processes.

The biggest constraint was space: [Allie]’s workspace had a fairly limited volume available, and the enclosure needed to hold an SLA printer, an isopropyl alcohol washing station, a UV curing chamber, and miscellaneous supplies. Most of the enclosure was made out of IKEA cabinets, using some large cabinets at the base to hold the printer and curing station, a countertop over these to hold the washing station, and more cabinets above to hold supplies. An MDF backing panel and acrylic side panels enclose the workspace between the cabinets. There was no safe way to exhaust fumes, so the enclosure recycles its air: a fan pulls air in through an activated-carbon filter mounted above the work area and into the plenum behind the chamber, from which it passes through the printer’s cabinet back into the workspace enclosure. Panel filters surround the carbon filter to catch particulate matter.

The enclosure uses four ESP32-based boards for automation: one uses a touchscreen to display data, and three are paired with BME680 sensors, primarily to report VOC concentrations. One, which also has a particulate matter sensor, senses air quality in the main chamber and plenum, one monitors air quality in the rest of the shop, and the third detects clogging from within the filter enclosure. The first real test of the chamber was to 3D print and paint some handles for the cabinets. It worked as expected, detecting the increased VOCs and ramping up the fan to keep them in check.

We’ve seen a ventilated printer enclosure before, that time for an FDM printer. Although their hazards are less blatant, they too can produce dangerous fumes, which could possibly be carcinogenic.

Thanks to [Keith Olson] for the tip!

A black-and-white clock face is shown. The numerals are ranged around the right edge of the clock. One pointer extends from the center of the clock, and one is on the left side of the face.

A Clock Inspired By Failed Cognitive Tests

May 27, 2026 by 85 Comments

One simple screening tool for cognitive impairment is the clock-drawing test (CDT): the patient is provided with a printed circle and asked to draw a clock face with the hands pointing to a certain time. Depending on how the clock is drawn, this could indicate a variety of different disorders, particularly dementia, with a particular deformity in the drawing sometimes pointing to a specific issue. These failed tests inspired [John Silvia] to create a clock with a unique, disordered face.

The numerals in this clock face are placed exclusively along the right half of the clock (in the test, this can be a sign of damage to the right parietal lobe, or of executive dysfunction caused by dementia), and out of order. The hour hand is controlled by a servo motor, and the minute hand is mounted on a separate, commercially-purchased clock mechanism on the left-hand side of the face.

The frame for the clock and the face are 3D-printed, and the servo motor is controlled by an ESP32-C3 with an RTC module. To minimize power draw, a MOSFET disconnects the servo motor from power except for the once-per-hour position update. Once per month, the ESP32 connects to Wi-Fi to synchronize to NTP time, otherwise remaining in a low-power state – even its indicator LEDs are disconnected to save power. These efforts paid off: when the servo isn’t active, it draws only about 160 µA, and a set of three AA NiMH cells lasts about a year.

Since the servo motor draws most of the power budget, it wouldn’t make much difference, but the ESP32’s co-processor can also be used for ultra-low-power projects. For a happier take on a drawing-related clock, check out one of these projects.

A phone running the XFCE desktop environment is placed on a desk, with a wireless keyboard in front of it.

Linux On Android Provides Inexpensive, Powerful Computing

May 26, 2026 by 60 Comments

In some parts of the world it’s common for cell service providers to sell new phones at a price significantly below market value, with the caveat that these phones are locked to that service provider alone. It’s questionable whether this practice is good for consumers, but as [Gabriel Broussard Korr] notes, it’s an opportunity for hackers: since it’s possible to run a Linux environment on these phones, they make an inexpensive source of quite powerful computing hardware.

In this case, [Gabriel] was using the Moto G Power 2024, which has 128 GB of storage, 12 GB of RAM, and costs less than $50 when carrier-locked. Rather than trying to install a mobile-oriented Linux distribution (such as postmarketOS), [Gabriel] installed Termux, a terminal emulator which provides a Linux environment within Android. Before doing this, he set up the phone and configured a number of settings for a better Linux experience. Since automatic updates can interfere with these settings, and since none of the provided settings effectively disable these, he used NetGuard to block Internet access from the updater app and from Google Play services.

The next step was to actually install Termux, as well as an X11 extension and an app which exposes an API for Termux. The desktop environment (XFCE in this case) was installed through Termux, and [Gabriel] wrote a shell script to go through the steps of starting it. XFCE worked well on mobile devices because of its full-desktop zoom capability. Even running Linux indirectly, the experience was smooth; [Gabriel] found that GIMP, Shotcut, and VS Code all performed well.

It’s not quite the same set of software, but we’ve previously featured a guide to setting up a similar Linux environment using Termux and AnLinux. Lindroid provides a similar containerized Linux environment; on the other hand, you can also use postmarketOS to make a server from an old phone.

A diagram of a neutron generator is shown in the top portion of the image, with the physical version below.

A Benchtop Neutron Generator For The Home Reactor

May 25, 2026 by 19 Comments

There are a surprising number of experiments an amateur nuclear physicist can perform, from making a Geiger counter to fusing hydrogen atoms in a fusor. One project which we haven’t seen before is a neutron generator, such as the benchtop neutron generator made by [Rapp Instruments] (translated).

This particular generator takes a feedstock of pure deuterium, which it ionizes and accelerates into a titanium target. The first deuterium nuclei to hit the target react with it to form titanium deuteride, immobilizing them until more ions strike them and they undergo nuclear fusion. The fusion reaction mostly forms helium-4, but sometimes forms helium-3 and a free neutron, which is radiated away. The radiated neutrons are slowed down by a block of high-density polyethylene, and a portion of them strike a silver or indium foil wrapped around a Geiger counter tube. The neutrons activate the silver or indium, and the Geiger counter detects the resultant increase in radioactivity.

The design is a linear particle accelerator built inside an evacuated glass tube. It uses two high-voltage power supplies: a 20 kV supply which ionizes the deuterium gas fed into the tube, and a 100 kV supply which accelerates ions emitted from the source into the target. The target itself is surrounded by a cup-shaped electrode to capture secondary electrons emitted during impact. To prevent arcing, the tube needs to be at a very low pressure, reached by extensive use of an oil diffusion pump.

Radioactivity measurements of the silver and indium foils showed that the generator did work; when irradiating the silver foil for five minutes, it generated 175 counts per second after the neutron source was turned off. Plotting the count rate versus time suggested that a mixture of two silver isotopes was being generated, Ag-110 and Ag-108, based on their half-lives. Irradiation of indium produced a similar exponential decay in radiation.

We recommend checking out the rest of the site; it’s a gold mine of projects, such as this mass spectrometer. For more background on neutron generators, we’ve covered their theory and some of the more common varieties.

A square red circuit board is shown on a black workbench. The circuit board houses two large chips in the upper left corner, each with a large heat sink attached.

Just How Bad Was The Intel IAPX432?

May 25, 2026 by 38 Comments

Processor design over the last few decades has moved toward RISC processors that aim to implement a few simple operations very efficiently. For a while, though, the trend was toward ever-more-complex CISC designs that let programmers implement complex behaviors using as few instructions as possible. Few processors took this approach further than the Intel iAPX432. This hyper-CISC processor was a commercial failure, largely due to its notoriously poor performance, but [MarkTheQuasiEngineer]’s benchmark suggests that this notoriety wasn’t totally deserved.

The first step before running a benchmark was to build a computer around the processor. The iAPX432 was implemented in three chips, two of which acted as the general data processor (GDP), and one of which handled input and output. [Mark] built an SBC (design and code here) that houses the two GDP chips and an FPGA for I/O. The 432 did have a well-deserved reputation for efficiently turning electricity into heat, and the original voltage regulator failed rather quickly.

The 432 was designed to use machine code which was almost a high-level language, with built-in object-oriented programming. It had over 200 operators, some of which implemented complex object-oriented operations, and a wide variety of data types, but it had no directly-accessible general-purpose registers. In addition to the lack of registers, it also had a very complex addressing system, allowing both direct and indirect addressing. For better performance, [Mark] used direct addressing.

For the benchmark, [Mark] implemented the Spigot algorithm to calculate the value of Pi. The results were somewhat surprising: calculating 2048 digits, it beat his previous retro-processor benchmarks; an Intel 8086 running the same algorithm took 2.5 times as long. Based on the results of this hand-written code, [Mark] speculates that the 432’s poor performance had more to do with poor compiler optimization than with the fundamental design.

We’ve covered some of the history of this troubled chip before. For a similarly ambitious but ill-fated Intel project, check out the history of Itanium.

A 3D-printed telescope with an infrared laser on the side is pointed out the window of a building at night.

Long-Range Night Vision With An Infrared Laser

May 18, 2026 by 18 Comments

Most consumer-grade night vision devices are basically a standard camera without the usual filter to block near infrared (NIR) light, which are then paired with a NIR light source that’s not visible to the human eye. Unlike the passive night vision provided by an image intensifier tube, these can’t resolve objects beyond the beam of their illumination source. On the other hand, if, as [Project 326] did, you use an infrared laser to illuminate the scene, you can still get a very long range out of these devices.

[Project 326]’s device consists of a previously-built reflecting telescope focusing a distant scene in to a webcam with the infrared filter removed, with the infrared laser illuminating the scene. Finding a suitable laser took some effort: the first option, a secondhand fiber-coupled industrial laser, was accidentally over-volted and destroyed during testing. The second had a fiber output which proved extremely hard to terminate, and a third laser couldn’t be collimated correctly. The final laser was a Vertical-Cavity Surface-Emitting Laser (VSEL) diode array element driven at about two Watts and collimated by a small lens.

This illumination setup is safe at a long range, but only at a long range. The laser was strong enough to burn cardboard at close range, but out at about 500 meters, the beam had spread until it was less than a hundredth of the standard safety limit. To make sure that nothing else would get in the way of the beam, it was shone down from the top of a tall building. Testing with a power meter also showed that at a long range, the beam was weaker than expected. It turned out that the wavelength used (940 nm) is attenuated by water vapor, to the point that up to 70% of the beam’s strength was lost before reaching the target. Despite this, and despite a rather linear beam profile, a somewhat dark image was still visible at 650 meters.

If you’re looking for a somewhat more versatile long-range night vision device, check out one based on an image intensifier. Another approach is to use a very high-sensitivity camera.

Continue reading “Long-Range Night Vision With An Infrared Laser” →