Machine Metal With Electricity: An EDM Attachment For 3D Printers

June 24, 2015 by Adam Fabio 54 Comments

[SuperUnknown] has revealed a secret project he’s been working on. He’s cooked up an EDM attachment for 3D printers, or any CNC machine for that matter. Electrical Discharge Machining (EDM) is a method of using sparks to machine metal. EDM isn’t a new technology, in fact commercial machines have been around since the 1960’s. If you’ve ever had an arc scar up your multimeter probes, you’ve unwittingly done a bit of EDM.

The theory behind EDM is simple: High voltage between the tool and workpiece causes sparks to jump between them. Each spark erodes the workpiece (and the tool). Big EDM machines perform their magic in a liquid which acts as both a dielectric and a flushing medium. This liquid can be anything from deionzed tap water to specially formulated oil. [SuperUnknown] is using good old-fashioned tap water.

As you can imagine, a single spark won’t erode much metal. EDM machines fire tens of thousands of times per second. The exact frequencies, voltages, and currents are secrets the machine manufacturers keep close to their chests. [SuperUnknown] is zeroing in on 65 volts at 2 amps, running at 35 kHz. He’s made some great progress, gouging into hardened files, removing broken taps from brass, and even eroding the impression of a coin in steel.

While we’d love to say this is a free open source project, [superUnknown] needs to pay the bills. He’s going with crowdsourced funding. No, not another Kickstarter. This project is taking a different route. The videos of the machine will be uploaded to YouTube and visible to [superUnknown’s] Patreon supporters. They will also be available for rent using YouTube’s new rental system. [SuperUnknown] has pledged to figure out a way to make the content available for starving college students and others with limited incomes.

Based upon his previous adventures with lil’ screwy, his homemade 100 ton press, and various other projects on the Arduino verses Evil YouTube channel, we think [superUnkown] has a pretty good chance of making home EDM work. Click past the break to see two videos of the 3D printer EDM toolhead in action. We should mention that [SuperUnknown] is rather colorful with his dialogue, so make sure you’re using headphones if you’re at work.

Continue reading “Machine Metal With Electricity: An EDM Attachment For 3D Printers” →

Castrol Virtual Drift: Hacking Code At 80MPH With A Driver In A VR Helmet

June 20, 2015 by Adam Fabio 29 Comments

Driving a brand new 670 horsepower Roucsh stage 3 Mustang while wearing virtual reality goggles. Sounds nuts right? That’s exactly what Castrol Oil’s advertising agency came up with though. They didn’t want to just make a commercial though – they wanted to do the real thing. Enter [Adam and Glenn], the engineers who were tasked with getting data from the car into a high end gaming PC. The computer was running a custom simulation under the Unreal Engine. El Toro field provided a vast expanse of empty tarmac to drive the car without worry of hitting any real world obstacles.

The Oculus Rift was never designed to be operated inside a moving vehicle, so it presented a unique challenge for [Adam and Glenn]. Every time the car turned or spun, the Oculus’ on-board Inertial Measurement Unit (IMU) would think driver [Matt Powers] was turning his head. At one point [Matt] was trying to drive while the game engine had him sitting in the passenger seat turned sideways. The solution was to install a 9 degree of freedom IMU in the car, then subtract the movements of that IMU from the one in the Rift.

GPS data came from a Real Time Kinematic (RTK) GPS unit. Unfortunately, the GPS had a 5Hz update rate – not nearly fast enough for a car moving close to 100 MPH. The GPS was relegated to aligning the virtual and real worlds at the start of the simulation. The rest of the data came from the IMUs and the car’s own CAN bus. [Adam and Glenn] used an Arduino with a Microchip mcp2515 can bus interface to read values such as steering angle, throttle position, brake pressure, and wheel spin. The data was then passed on to the Unreal engine. The Arduino code is up on Github, though the team had to sanitize some of Ford’s proprietary CAN message data to avoid a lawsuit. It’s worth noting that [Adam and Glenn] didn’t have any support from Ford on this, they just sniffed the CAN network to determine each message ID.

The final video has the Hollywood treatment. “In game” footage has been replaced with pre-rendered sequences, which look so good we’d think the whole thing was fake, that is if we didn’t know better.

Click past the break for the final commercial and some behind the scenes footage.

Continue reading “Castrol Virtual Drift: Hacking Code At 80MPH With A Driver In A VR Helmet” →

Hacklet 52 – Breakout Board Projects

June 19, 2015 by Adam Fabio 18 Comments

Starting a design with a new part can be hard. What power supply voltage(s) does it need? Are there any support component requirements? What is the footprint? What about the I/O voltage levels? Breakout boards are designed to answer all those questions for you. Breakouts help when you’re designing with a new part – be it a microcontroller, a sensor, a motor driver, or anything else. They also are a huge help when you’re trying to knock out a quick hack, and just need to get something working quick. Fast to integrate, often breadboard friendly, breakouts just make things easier! This week’s Hacklet is about some of the best breakout board projects on Hackaday.io!

We start with [Christoph] and STM32F030F4P6 breakout board. Inspired by the Teensy 3.0, [Christoph] set out to build a simple, easy to use, and small breakout board for an ARM processor. The STM32F030F4P6 is a great starting point. At only 20 pins, it’s one of the smallest ARM based chips around. He added the basic things needed to bring this chip up: decoupling caps, a reset button, headers for ST’s software debugger, and of course an LED for a blinky hello world program. The resulting board is physically tiny, but this lilliputian ARM board packs Coretex M0 powered punch!

Next up is [al1] and DRV8836 Breakout. Sooner or later, everyone wants to drive a motor in one of their projects. It’s a rite of passage, just like blinking an LED. Motors pull a lot of current though, so external transistors or driver chips are almost always necessary. TI’s DRV8836 chip packs two full H-bridges into one package. That’s enough to drive two DC motors or one stepper. Handling 1.5 amps of current per driver in a tiny package means that thermal coupling is important. The DRV8836 has a large thermal pad which has to be soldered to keep the magic smoke in. [al1] dropped the chip, along with the correct thermal footprint and decoupling capacitors onto a simple breakout. The result is easy to use motor drivers for the masses.

Hackaday.io power user [davedarko] took cues from his favorite designs to create Ignore this ESP8266 board. In [Dave’s] own words, “I stole from every one. The huzza from Adafruit, [Matt’s] breakout board, [Al1s] board, NodeMCUs DevKit.” Hey [Dave] there’s no stealing in open source hardware! There is only design reuse with attribution, which is exactly what you’re doing. [Dave’s] breakout can use both popular ESP8266 footprints: the ESP-01 and ESP-12. He’s added power, reset/programming buttons, and the all important serial header to talk to the module. Going serial allows dave to keep costs down by not including an expensive serial to USB chip in the BOM. Most of us have FTDI cables (or clones) bouncing hanging around anyway. We definitely like the logo on this one!

Finally we have [The Big One] with uBBB 32u4. uBBB 32u4 is a bigger brother of µbbb, a Hackaday.io project [Warren] and [The Big One] worked on. µbbb uses an Atmel ATmega32u2 processor. [The Big One] has expanded the faimly to include an ATmega32u4. If you’re wondering, uBBB stands for “Micro Bare Bones Board” At 1.65″ x 0.8″, this is a micro board. It still manages to include everything you need to get the processor up and running fast. Crystal, buttons, decoupling caps, and LEDs – everything is here. A mini USB connector makes communicating with the ATmega a snap!

If you want to see more breakout boards, check out our new breakout board list! If I’ve forgotten to add you to the list, just drop me a message on Hackaday.io. That’s it for this week’s Hacklet, As always, see you next week. Same hack time, same hack channel, bringing you the best of Hackaday.io!

Caption CERN Contest – Work Until You Drop

June 19, 2015 by Adam Fabio 12 Comments

Week 19 of the Caption CERN Contest is now in the record books, though we’re sure we’ll be getting “safety update” emails from HR about the incident for the next several weeks. Thanks to everyone who threw caution to the wind and submitted a caption! This definitely is some sort of medical or emergency room at CERN. We’re still not quite clear as to why they need a full-sized skeleton though. We have to wonder how many lab pranks that poor former-human has been part of.

The Funnies:

“The second test subject survived a bit better than the first, and if you’re wondering, the first test subject is standing in the corner”- [jakewisher125]
“It soon became apparent that it had been a mistake to entrust site security to sharks with lasers.” -[Robb Smith]
“What do you mean blink once if it hurts? Are you serious?” – [Rollyn01]

This week’s winner is [Will Frankian] with “Dr. Banks never tried eyeballing the electron beam alignment again”. Congrats [Will]! Enjoy your LightBlue Bean from The Hackaday Store!

Week 20

Anyone who’s worked on a major project, be it professional, personal, or for a contest like The Hackaday Prize, knows about marathon sessions. Those times when you put in your all and just push the project ahead until you drop. This scientist has definitely given his all and then some! He’s catching a few winks right under the blackboard where he presumably has been working. This image has no caption, though it’s attached to an album entitled Linac control room. None of the pictures seem to show much of a control room though. It seems that back in 1966, CERN’s photographer was a bit more interested in the sleeping scientists than the science itself!

What do you think is happening in this image? Can you make anything interesting out from the diagrams on the blackboard? Give it a shot! This week’s prize is a Stickvice from The Hackaday Store.

Add your humorous caption as a comment to this project log. Make sure you’re commenting on the contest log, not on the contest itself. As always, if you actually have information about the image or the people in it, let CERN know on the original image discussion page.

Good Luck!

Phonographs Through The Eye Of An Electron Microscope

June 16, 2015 by Adam Fabio 32 Comments

Hackaday Prize judge [Ben Krasnow] has been busy lately. He’s put his scanning electron microscope (SEM) to work creating an animation of a phonograph needle playing a record. (YouTube link) This is the same 80’s SEM [Ben] hacked back in November. Unfortunately, [Ben’s] JSM-T200 isn’t quite large enough to hold an entire 12″ LP, so he had to cut a small section of a record out. The vinyl mods weren’t done there though. SEMs need a conductive surface for imaging. Vinyl is an insulator. [Ben] dealt with this by using his vacuum chamber to evaporate a thin layer of silver on the vinyl.

Just imaging the record wouldn’t be enough; [Ben] wanted an animation of a needle traveling through the record grove. He tore apart an old phonograph needle and installed it in on a copper wire in the SEM. Thanks to the dual stage setup of the JSM-T200, [Ben] was able to move the record-chip and needle independently. He could then move the record underneath the needle as if it were actually playing. [Ben] used his oscilloscope to record 60 frames, each spaced 50 microns apart. He used octave to process the data, and wound up with the awesome GIF animation you see on the left.

[Ben] wasn’t done though. He checked out a few other recording formats, including CD and DVD optical media, and capacitance electronic disc, an obscure format from RCA which failed miserably in the market. The toughest challenge [Ben] faced was imaging the CD media. The familiar pits of a CD are stored on a thin aluminum layer sandwiched between the lacquer label and the plastic disc. He tried dissolving the plastic with chemicals, but enough plastic was left behind to distort the image. The solution turned out to be double-sided tape. Sticking some tape down on the CD and peeling it off cleanly removed the aluminum, and provided a sturdy substrate with which to mount the sample in the SEM.

We’re curious if stereo audio data can be extracted from the SEM images. [Oona] managed to do this with a mono recording from a toy robot. Who’s going to be the first one to break out the image analysis software and capture some audio from [Ben’s] images?

Continue reading “Phonographs Through The Eye Of An Electron Microscope” →

Get Up, Stand Up. With A Little Help From The Mindfulness Bracelet

June 16, 2015 by Adam Fabio 10 Comments

[Becky Stern] has created the mindfulness bracelet, a wearable which looks great and serves an important purpose. The bracelet buzzes every hour to remind you to stand up and take a break from work, soldering, gaming, or whatever it is you may be doing. The bracelet is made up of interlinked figure 8 shapes of leather, though [Becky] says rubber from a bicycle inner tube works great as well. The final shape reminds us of the link belts sometimes found on lathes or other industrial equipment. The links are the perfect size to slip an Arduino Gemma in, along with a battery and vibrating motor. A NPN transistor, diode, and resistor round out the entire bill of materials for this design. This bracelet is a heck of a lot cheaper than the Apple watch feature which inspired it!

The time interval is set in the code to 1 hour, and can be adjusted by the user. Although the times are stored in milliseconds, the design does use the ATtiny85’s Watchdog Timer (WDT) to conserve power. This means the time can drift up to 30 seconds per hour, which is fine in this application.

Click past the break to see the bracelet in action!

Continue reading “Get Up, Stand Up. With A Little Help From The Mindfulness Bracelet” →

Hacklet 51 – Crowdfunding Projects

June 12, 2015 by Adam Fabio 6 Comments

Ah crowdfunding. You might say we have a love/hate relationship with it here at Hackaday. We’ve seen some great projects funded through sites like Kickstarter, IndieGoGo, and the like. We’ve also seen projects where the creators were promising more than they could deliver. While the missed deliveries and outright scams do get a lot of press, we believe that crowdfunding in general is a viable platform for getting a project funded.

Closer to home, Hackaday.io hosts thousands of projects. It’s no surprise that some of these have had crowdfunding campaigns. This week’s Hacklet focuses on those projects which have taken the leap into the crowdfunding arena.

We start with [Louis Beaudoin] and SmartMatrix. [Louis] has created an awesome Teensy 3.1 based system for displaying images, animated graphics, and random patterns on a 32×32 RGB LED panel. The LED panel is the same type used in commercial LED billboards. SmartMatrix is open source, and includes extra pins for hacking. Our own [Mike Szczys] hacked the SmartMatrix to create a 1-pixel PacMan clone. [Louis’] Kickstarter is almost over, and needs a huge boost for fully-assembled SmartMatrix to make its goal. Even if the campaign isn’t successful, we think its a great project and you can always get a solder-it-yourself kit from The Hackaday Store!

Next up is [Michael R Colton] with PortableSDR. PortableSDR was one of the five finalists in The 2014 Hackaday Prize. This pocket-sized software defined radio transceiver started as a ham radio project: a radio system which would be easy for hams to take with them on backpacking trips. It’s grown into so much more now, with software defined radio reception and transmission, vector network analysis, antenna analysis, GPS, and a host of other features. [Michael] raised a whopping $66,197 in his Kickstarter campaign, and he’s already delivered the hand assembled prototypes to their respective backers! Even the lower level rewards are awesome – [Michael’s] PSDR key chains are actually PCBs which can be turned into maple compatible ARM devboards with just about $10 of additional parts.

Next we have The ChipWhisperer, [Colin Flynn’s] embedded security testing system, which won second place in the 2014 Hackaday Prize. We’ve covered both [Colin] and the ChipWhisperer several times on the Blog. You can always buy the full ChipWhisperer from [Colin’s] company, NewAE Technology Inc. At $1500 USD, the ChipWhisperer is incredibly affordable for a hardware security tool. That price is still a bit high for the average hacker though. [Colin] created a Kickstarter campaign for a light version of the ChipWhisperer. This version is a great platform for learning hardware security, as well as an instrument for testing embedded systems. The campaign was a huge success, raising $72,079.

Not every crowdfunding project has to be a massive megabuck effort though. [ZeptoBit] just wanted to solve a problem, he needed a WiFi shield for Arduino using an ESP8266 module. ESP8266 WiFi modules have been all the rage for months now, but they can be a bit of a pain to wire up to an Arduino Uno. The dual row .100 headers are not bread board friendly. The ESP8266’s 3.3 V power and interface requirements mean that a regulator and level shifters are needed to get the two boards working together. [ZeptoBit] put all that and more on his wingboard. It worked so well that he launched a Kickstarter campaign for a small run of boards – his initial goal was kr3,500, or $425 USD. He ended up raising kr13,705, or $1665 USD. Not bad at all for a hobby project!

If this isn’t enough crowdfunding goodness for you, check out our Crowdfunding list! That’s it for this week’s Hacklet, As always, see you next week. Same hack time, same hack channel, bringing you the best of Hackaday.io!