Colorful Fan And LED Controller For 3D Printer

April 11, 2016 by Gerrit Coetzee 5 Comments

[Dave] just couldn’t take the ambient noise from his Lulzbot Mini anymore, so he built a fancy fan controller for it.

He measured some points on the printer’s Rambo controller board to see what actually got hot during a print. The hottest components were the motor drivers, so he taped a thermistor to them. He also placed one in the printer’s power supply. He replaced the main fan with a low noise model from Noctua (which have the most insanely fancy packaging you could imagine for a computer fan). The software on an Arduino Nano now idles the fan at an inaudible 650RPM, if an unacceptable temperature increase is detected, it increases the fan speed for a period, keeping everything nice and quietly cool.

The graphics display was added because, “why not?” A classic reason. The graphics runs on a hacked version of Adafruit’s library. It took him quite a while to get the graphics coded, but they add that extra bit of high-tech flair to keep the cool factor of the 3d printer up before they become as ubiquitous as toasters in the home. The code, fritzing board layout, 3D models, and a full build log is available at his site.

Brazillian Class Creates Digital Board Game

April 10, 2016 by Gerrit Coetzee 10 Comments

A class in Brazil was given the assignment to make a board game. [Marcelo], presumably, heard his son lamenting how lame it was going to be if the board was just cardboard with some drawings on, and came to the rescue.

fusion between Operation and one of those disease transmitters at the doctors office — A match meant to be.

Working with the class, they came up with the rules of the game. We’re not certain what those are, but it involves a regular game board, a flashing light circle with numbers, and a fusion between Operation and one of those disease transmitters commonly found at the doctor’s office. You can try to puzzle them out from the video after the break.

The brains of the board is an Arduino with an external EEPROM for all the sound effects and other data needed for this construction. Everything is laid out on a beautifully done home etched PCB. It’s too bad the other side of the board isn’t visible.

We’re sure the kids learned a lot working with [Marcelo]. It would have been nice if a traveling wizard came to some of our earlier classes in school and showed us just how much cool stuff you can do if you know electronics.

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A Comparison Of Early Graphics Cards

April 9, 2016 by Gerrit Coetzee 10 Comments

We have to admit, we expected to be bored through [The 8-Bit Guy]’s presentation, only to stay riveted through his comparison of early graphic card technology.

Some presentations get a bit technical, which isn’t bad, but what is so interesting about this one is the clear explanation of what the market was like, and what it was like for the user during this time. For example, one bit we found really interesting was the mention of later games not supporting some of the neat color hacks for CGA because they couldn’t emulate it fully on the VGA cards they were developing on. Likewise, It was interesting to see why a standard like RGBI even existed in the first place with his comparison of text in composite, and much clearer text in RGBI.

We learned a lot, and some mysteries about the bizarre color choices in old games make a lot more sense now. Video after the break.

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Robotic Vacuums Get Torn-down For Design Showdown.

April 8, 2016 by Gerrit Coetzee 7 Comments

Fictiv runs a 3D printing shop. They have a nice interface and an easy to understand pricing scheme. As community service, or just for fun, they decided to tear-down two robot vacuums and critique their construction while taking really nice pictures.

The first to go is the iRobot 650 model. For anyone who’s ever taken apart an iRobot product, you’ll be happy to know that it’s the same thousand-screws-and-bits-of-plastic ordeal that it always was. However, rather than continue their plague of the worst wire routing imaginable, they’ve switched to a hybrid of awfulness and a clever card edge system to connect the bits and pieces.

The other bot is the Neato XV-11. It has way fewer screws and plastic parts, and they even tear down the laser rangefinder module that’s captured many a hacker’s attention. The wire routing inside the Neato is very well done and nicely terminated in hard-to-confuse JST connectors. Every key failure point on the Neato, aside from the rangefinder, can be replaced without disassembling the whole robot. Interestingly, the wheels on both appear to be nearly identical.

In the end they rate the Neato a better robot, but the iRobot better engineered. Though this prize was given mostly for the cleverness of the card edge connectors.

Put Words In Your Dog’s Mouth With A Talking Dog Collar

April 7, 2016 by Gerrit Coetzee 21 Comments

It’s just a little past Halloween, but Adafruit’s talking dog collar, modeled after the movie Up, is still a nice fusion between crafting and hacking.

One reason that Adafruit is so popular is that every time they sell us something, they give us some of the worlds best tutorials and libraries for free. For this project they’re using their Bluetooth LE board and their Audio FX board with a few more mundane vitamins to construct the collar. We’re sure the enterprising hacker could find alternatives if they so choose.

The collar is made of leather and 3D printed props. They went with alkaline batteries rather than lithium, to keep their doggy companion a little safer. All the electronics are hidden under the various props and the wiring is routed behind the belt. To control the app, the different sound bytes are mapped to buttons on their Bluetooth-to-serial phone app.

It’s a good starter tutorial, and the concept applied differently would definitely be good for at least one good prank on a coworker or friend.

A Look Into The Future Of Slicing

April 7, 2016 by Gerrit Coetzee 48 Comments

I’ve had a few conversations over the years with people about the future of 3D printing. One of the topics that arises frequently is the slicer, the software that turns a 3D model into paths for a 3D printer. I thought it would be a good idea to visualize what slicing, and by extension 3D printing, could be. I’ve always been a proponent of just building something, but sometimes it’s very easy to keep polishing the solution we have now rather than looking for and imagining the solutions that could be. Many of the things I’ll mention have been worked on or solved in one context or another, but not blended into a cohesive package.

I believe that fused deposition modelling (FDM), which is the cheapest and most common technology, can produce parts superior to other production techniques if treated properly. It should be possible to produce parts that handle forces in unique ways such that machining, molding, sintering, and other commonly implemented methods will have a hard time competing with in many applications.

Re-envisioning the slicer is no small task, so I’m going to tackle it in three articles. Part One, here, will cover the improvements yet to be had with the 2D and layer height model of slicing. It is the first and most accessible avenue for improvement in slicing technologies. It will require new software to be written but does not dramatically affect the current construction of 3D printers today. It should translate to every printer currently operating without even a firmware change.

Part Two will involve making mechanical changes to the printer: multiple materials, temperatures, and nozzle sizes at least. The slicer will need to work with the printer’s new capabilities to take full advantage of them.

Finally, in Part Three, we’ll consider adding more axes. A five axis 3D printer with advanced software, differing nozzle geometries, and multi material capabilities will be able to produce parts of significantly reduced weight while incorporating internal features exceeding our current composites in many ways. Five axis paths begin to allow for weaving techniques and advanced “grain” in the layers put down by the 3D printer.

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Take The Long Road To A Precise Laser PCB Exposer

April 6, 2016 by Gerrit Coetzee 23 Comments

According to [diyouware], inside of every HD-DVD player is a gem of laser engineering with the designation of PHR-803T, and it’s just begging to be converted into a PCB exposer. Following along similar hacks which tore the laser diode out of Blu-ray players to expose PCBs, they wanted to use the whole PHR-803T unit without disassembling it, and to try to enable all of its unique features.

They envisioned something simple like a scanner for their machine. Just place the PCB on top of a glass sheet, close the lid, and click print. Unfortunately, moving the laser itself just caused too much vibration. So they switched to an inverted delta robot and named it TwinTeeth. In this design, the laser would stay still and the PCB would move.

What follows next is a seriously impressive journey in reverse engineering and design. The PHR-803T had no data sheet, but a ton of features. For example, it can autofocus, and has three different laser diodes. So many interesting problems were found and solved. For example, the halo from the laser caused the surrounding photoresist to cure. They solved it by adding a glass plate with a UV filtering film on it. Only the most focused point of the laser could punch through.

Another adventure was the autofocus. They wanted to autofocus on all four corners of the board. The PHR-803T was designed to read HD-DVDs so can focus a beam to far below 0.01 mm. They got autofocus working with the UV laser, but couldn’t use it on the PCB without curing the photoresist. So they put a piece of aluminum foil at a known level to start. Then they realized they could use the red or infrared diodes to focus instead. Now they can level the PCB in software, and focus the diode without curing the photoresist.

In the end they have an inverted-delta mini PCB factory. It can produce boards around the size of an Arduino shield with a resolution of 600 DPI. Their machine also has attachments for drilling and solder paste dispensing. Check out the video of it in action.
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