Author: Bryan Cockfield

1851 Articles

Electroplating 3D Printed Parts For Great Strength

March 1, 2021 by 33 Comments

Resin 3D printers have a significant advantage over filament printers in that they are able to print smaller parts with more fine detail. The main downside is that the resin parts aren’t typically as strong or durable as their filament counterparts. For this reason they’re often used more for small models than for working parts, but [Breaking Taps] wanted to try and improve on the strength of these builds buy adding metal to them through electroplating.

Both copper and nickel coatings are used for these test setups, each with different effects to the resin prints. The nickel adds a dramatic amount of stiffness and the copper seems to increase the amount of strain that the resin part can tolerate — although [Breaking Taps] discusses some issues with this result.

While the results of electroplating resin are encouraging, he notes that it is a cumbersome process. It’s a multi-step ordeal to paint the resin with a special paint which helps the metal to adhere, and then electroplate it. It’s also difficult to ensure an even coating of metal on more complex prints than on the simpler samples he uses in this video.

After everything is said and done, however, if a working part needs to be smaller than a filament printer can produce or needs finer detail, this is a pretty handy way of adding more strength or stiffness to these parts. There’s still some investigating to be done, though, as electroplated filament prints are difficult to test with his setup, but it does show promise. Perhaps one day we’ll be able to print with this amount of precision using metal directly rather than coating plastic with it.

Thanks to [smellsofbikes] for the tip!

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Reliable Frequency Reference From GPS

February 28, 2021 by 35 Comments

GPS technology is a marvel of the modern world. Not only can we reliably locate positions on the planet with remarkable accuracy and relatively inexpensive hardware, but plenty of non-location-based features of the technology are available for other uses as well. GPS can be used for things like time servers, since the satellites require precise timing in order to triangulate a position, and as a result they can also be used for things like this incredibly accurate frequency reference.

This project is what’s known as a GPSDO, or GPS-disciplined oscillator. Typically they use a normal oscillator, like a crystal, and improve its accuracy by pairing it with the timing signal from a GPS satellite. This one is a standalone model built by [Szabolcs Szigeti] who based the build around an STM32 board. The goal of the project was purely educational, as GPSDOs of various types are widely available, but [Szabolcs] was able to build exactly what he wanted into this one including a custom power supply, simple standalone UI, and no distribution amplifier.

The build goes into a good bit of detail on the design and operation of the device, and all of the PCB schematics and source code are available on the projects GitHub page if you want to build your own. There are plenty of other projects out there that make use of GPS-based time for its high accuracy, too, like this one which ties a GPS time standard directly to a Raspberry Pi.

A Nerf Gun Upgrade

February 18, 2021 by 16 Comments

A lot of us have nostalgia for our childhood toys, and as long as they’re not something like lawn darts that nostalgia often leads to fun upgrades since some of us are adults with industrial-sized air compressors. Classics like Super Soakers and Nerf guns are especially popular targets for improvements, and this Nerf machine gun from [Emiel] is no exception.

The build takes a Nerf ball-firing toy weapon and basically tosses it all out of the window in favor of a custom Nerf ball launching rifle. He starts with the lower receiver and machines a pneumatic mechanism that both loads a ball into the chamber and then launches it. This allows the rifle to be used in both single-shot mode and also in fully-automatic mode. From there, a barrel is fashioned along with the stock and other finishing touches.

[Emiel] also uses a high-speed camera to determine the speed of his new Nerf gun but unfortunately it isn’t high-speed enough, suffering from the same fate as one of the fastest man-made objects ever made, and he only has a lower bound on the speed at 400 km/h. If you don’t want to go fast with your Nerf builds, though, perhaps you should build something enormous instead. Continue reading “A Nerf Gun Upgrade” →

Steam Engine Replica From LEGO

January 25, 2021 by 25 Comments

If engineering choices a hundred years ago had been only slightly different, we could have ended up in a world full of steam engines rather than internal combustion engines. For now, though, steam engines are limited to a few niche applications and, of course, models built by enthusiasts. This one for example is built entirely in LEGO as a scale replica of a steam engine originally produced in 1907.

The model is based on a 2500 horsepower triple-expansion four-cylinder engine that was actually in use during the first half of the 20th century. Since the model is built using nothing but LEGO (and a few rubber bands) it operates using a vacuum rather than with working steam, but the principle is essentially the same. It also includes Corliss valves, a technology from c.1850 that used rotating valves and improved steam engine efficiency dramatically for the time.

This build is an impressive recreation of the original machine, and can even run at extremely slow speeds thanks to a working valve on the top,  allowing its operation to be viewed in detail. Maximum speed is about 80 rpm, very close to the original machine’s 68 rpm operational speed. If you’d prefer your steam engines to have real-world applications, though, make sure to check out this steam-powered lawnmower.

Thanks to [Hari] for the tip!

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Automated Balcony Shade Uses NFC

January 20, 2021 by 3 Comments

[Udi] lives in an apartment with a pleasant balcony. He also has three kids who are home most of the time now, so he finds himself spending a little more time out on the balcony than he used to. To upgrade his experience, he installed a completely custom shade controller to automatically open and close his sunshade as the day progresses.

Automatic motors for blinds and other shades are available for purchase, but [Udi]’s shade is too big for any of these small motors to work. Finding a large servo with a 2:1 gear ration was the first step, as well as creating a custom mount for it to attach to the sunshade. Once the mechanical situation was solved, he programmed an ESP32 to control the servo. The ESP32 originally had control buttons wired to it, but [Udi] eventually transitioned to NFC for limit switch capabilities and also implemented voice control for the build as well.

While not the first shade controller we’ve ever seen, this build does make excellent use of appropriate hardware and its built-in features and although we suppose it’s possible this could have been done with a 555 timer, the project came together very well, especially for [Ubi]’s first Arduino-compatible build. If you decide to replicate this build, though, make sure that your shade controller is rental-friendly if it needs to be.

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Extensive Modification Of DSLR Includes High Quality Audio

January 15, 2021 by 15 Comments

Modern DSLR cameras are incredible pieces of technology that can take excellent high-quality photos as well as record video and audio. However, as they become jacks of all trades they risk being masters of none, and the audio quality in modern DSLRs certainly reflects that old cliche. To get true high-quality audio while recording with a camera like this Canon 80d, you’ll either need a secondary audio recording device or you’ll need to interface one directly into the camera itself.

This build from [Tony] aka [Carnivore] goes into the inner workings of the camera to add an audio mixer to the camera’s audio input, allowing for multiple audio streams to be recorded at once. First, he removed the plastic around the microphone port and attached a wire to it that extends out of the camera to a 1/8″ plug. While he had the case open he also wired a second shutter, added a record button to a custom location on the front of the camera, and bypassed a switch which prevents the camera from operating if the battery door isn’t closed.

With those modifications in place, he removed the internal flash from the camera before closing the body. A custom 3D printed mount was placed in the vacant space which now houses the audio mixer, a SR-AX100 from Saramonic. This plugs in to the new microphone wire from earlier in the build, allowing the camera to have an expanded capacity for recording audio.

While [Tony] has a fairly unique use case for all of these modifications to an already $1000 camera, getting into the inner workings of DSLRs isn’t something to shy away from if you need something similar done. We’ve even seen modifications to cameras like these to allow for watercooling during video recording.

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Dynamic Map Of Italy On A PCB

January 14, 2021 by 9 Comments

While most PCBs stick to tried-and-true methods of passing electrons through their layers of carefully-etched copper, modern construction methods allow for a large degree of customization of most aspects of these boards. From solder mask to number of layers, and even the shape of the board itself, everything is open for artistic license and experimentation now. [Luca] shows off some of these features with his PCB which acts as a live map of Italy.

The PCB is cut out in the shape of the famous boot, with an LED strategically placed in each of 20 regions in the country. This turns the PCB into a map with the RGB LEDs having the ability to be programmed to show any data that one might want. It’s powered by a Wemos D1 Mini (based on an ESP8266) which makes programming it straightforward. [Luca] has some sample programs which fetch live data from various sources, with it currently gathering daily COVID infection rates reported for each of the 20 regions.

The ability to turn a seemingly boring way to easily attach electronic parts together into a work of art without needing too much specialized equipment is a fantastic development in PCBs. We’ve seen them turned into full-color art installations with all the mask colors available, too, so the possibilities for interesting-looking (as well as interesting-behaving) circuits are really opening up.

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