Over-Engineered Incandescent Numerical Display Shows Great Workmanship

April 1, 2021 by Donald Papp 18 Comments

Back before LED technology came into its own, displays used incandescent bulbs. These vintage incandescent displays weren’t necessarily big; the Eaton 925H-C fiber optic display, for example, has numbers barely 7 mm tall and packs two of them into a tiny area. Of course, the depth of the display module itself is huge by today’s standards; those components have got to go somewhere, after all.

This particular device is, in [Industrial Alchemy]’s words, “[d]ripping with the spending excess that only a bottomless military budget can provide… the Eaton 925H-C may not be a practical device, but it is certainly an impressive one.”

The way the display works is this: individual incandescent bulbs light up fiber optic light guides, which terminate on the face of the display in small dots to make up a numerical display. With only fourteen bulbs, the dots we see here clearly aren’t individually addressable; the two digits are most likely broken up into seven segments each, with three dots making up each segment.

No expense seems spared in the design and manufacture of these displays. Even the incandescent lamps have individual shock absorbers.

The sheer amount of workmanship in these displays is remarkable, and their design makes them easy to retrofit with LED technology instead of replacing the tiny incandescent lamps. In a stark contrast to all of the machined aluminum and gold plated contacts seen here in the Eaton 925H-C, take a look at this Soviet-era seven-segment incandescent display whose construction is far less sophisticated, but shows off its own clever engineering. We’ve also seen more modern DIY takes on the concept, using LED light sources and cured UV resin light pipes to get that vintage look to the displays.

To Lovers Of Small Boxes: A 3D Printable Design Just For You

March 28, 2021 by Donald Papp 7 Comments

Print them at 50% scale for a far cuter (and much less useful) result.

[Jacob Stanton]’s design for 3D-printable, stacking and locking boxes is a great example of design for manufacturability (DFM). MicroStacks show how part of good DFM is taking the manufacturing method’s strengths and weaknesses into account. [Jacob]’s boxes are created specifically with 3D printing in mind, which is great design whether somebody is making one, or dozens.

The boxes have sturdy parts that all print without any need for supports, fasteners, or post-processing. In addition, since no two 3D printers are quite alike and some print better than others, the parts are also designed to be quite forgiving of loose tolerances. Even on a printer that is less well-tuned than it could be, the design should still work. The boxes also have a nice stacking feature: a sturdy dovetail combined with a sliding tab means that once boxes are stacked, they’re not coming apart by accident unless something breaks in the process.

The boxes as designed are about big enough to store AA cells. Not the right size for you? One nice thing about a 3D-printable design that doesn’t need supports is that it’s trivial to uniformly scale the size of the models up or down to match one’s needs without introducing any print complications in the process. You can watch [Jacob] assemble and demonstrate his design in the video, embedded below.

Continue reading “To Lovers Of Small Boxes: A 3D Printable Design Just For You” →

Archery Release Becomes Reusable Balloon Cutdown Mechanism

March 27, 2021 by Donald Papp 12 Comments

A cutdown in high-altitude balloon (HAB) parlance refers to detaching a payload, and can refer to the act of severing a line or to the mechanism itself. How is this done? The most common way is the “hot wire” method: a segment of wire is heated rapidly with a high current, causing it to melt through something like a nylon line.

But there’s more than one way to solve a problem, and while documenting different cutdown methods, [KI4MCW] found that a caliper-style archery release plus hobby servo could be used as a high strength cutdown mechanism. An archery release (or bow release) is a tool to assist in holding the string of a bow in the drawn position, and cleanly release it at the touch of a lever or button. It occurred to [KI4MCW] that these features might be made to serve as a payload release as well, and you can see here the crude but successful prototype for a reusable cutdown.

The archery release [KI4MCW] obtained opens its jaws when a trigger-style lever on the side is pulled. The force required to trigger this is remarkably low, and a low-torque economical hobby servo easily does the job. In fact, the force needed to trip the release is so low that [KI4MCW] added a short rubber band to provide some opposing tension on the lever, just to be sure no spontaneous triggers occurred. The device hasn’t flown yet, but the prototype looks promising. Maybe a mechanism like this would be appropriate for a payload like dropping a high-altitude RC glider from a balloon.

Get A Better Look At E3D’s Tool-changing 3D Printer Kit

March 20, 2021 by Donald Papp 4 Comments

Want a closer, in-depth look at E3D’s motion system and tool-changing platform? [Kubi Sertoglu] shared his impressions after building and testing the system, which comes in the form of a parts bundle direct from E3D costing just under $3000 USD. The project took [Kubi] about 15 hours and is essentially built from the ground up. The system is definitely aimed at engineers and advanced prosumers, but [Kubi] found it to be of remarkable quality, and is highly pleased with the end results.

E3D Motion system and toolchanger, with four extruders

We first saw E3D’s design announced back in 2018, when they showed their working ideas for a system that combined motion control and a toolchanger design. The system [Kubi] built uses four 3D printing extruders for multi-material prints, but in theory the toolheads could just as easily be things like grippers, lasers, or engravers instead of 3D printing extruders.

One challenge with tool changing is ensuring tools mount and locate back into the same place, time after time. After all, a few fractions of a millimeter difference in the position of a print head would spell disaster for the quality of most prints. Kinematic couplings are the answer to being sure something goes back where it should, but knowing the solution is only half the battle. Implementation still requires plenty of clever design and hard engineering work, which is what E3D has delivered.

Want a closer look at the nitty-gritty? Check out E3D’s GitHub repository for all the details on their toolchanger and motion system.

New Part Day: Onion Tau LiDAR Camera

March 18, 2021 by Donald Papp 40 Comments

The Onion Tau LiDAR Camera is a small, time-of-flight (ToF) based depth-sensing camera that looks and works a little like a USB webcam, but with a really big difference: frames from the Tau include 160 x 60 “pixels” of depth information as well as greyscale. This data is easily accessed via a Python API, and example scripts make it easy to get up and running quickly. The goal is to be an affordable and easy to use option for projects that could benefit from depth sensing.

When the Tau was announced on Crowd Supply, I immediately placed a pre-order for about $180. Since then, the folks at Onion were kind enough to send me a pre-production unit, and I’ve been playing around with the device to get an idea of how it acts, and to build an idea of what kind of projects it would be a good fit for. Here is what I’ve learned so far.

Continue reading “New Part Day: Onion Tau LiDAR Camera” →

Perlin Noise Helps Make Trippy Typographic Art

March 10, 2021 by Donald Papp 8 Comments

Perlin noise is best explained in visual terms: if a 2D slice of truly random noise looks like even and harsh static, then a random 2D slice of Perlin noise will have a natural-looking blotchy structure, with smooth gradients. [Jacob Stanton] used Perlin noise as the starting point for creating some interesting generative vector art that shows off all kinds of different visuals. [Jacob] found that his results often exhibited a natural quality, with the visuals evoking a sense of things like moss, scales, hills, fur, and “other things too strange to describe.”

The art project [Jacob] created from it all is a series of posters showcasing some of the more striking examples, each of which displays an “A” modified in a different way. A few are shown here, and a collection of other results is also available.

Perlin noise was created by Ken Perlin while working on the original Tron movie in the early 80s, and came from a frustration with the look of computer generated imagery of the time. His work had a tremendous and lasting impact, and was instrumental to artists creating more natural-looking textures. Processing has a Perlin noise function, which was in fact [Jacob]’s starting point for this whole project.

Noise, after all, is a wide and varied term. From making generative art to a cone of silence for smart speakers, it has many practical and artistic applications.

High-Altitude Balloon Tracker Does Landing Prediction With Pi Pico

March 10, 2021 by Donald Papp 1 Comment

[Dave Akerman]’s ongoing high altitude balloon (HAB) work is outstanding, and we’re all enriched by the fact that he documents his work like he does. Recently, [Dave] wrote about his balloon tracker based on the Raspberry Pi Pico, whose capabilities brought a couple interesting features to the table.

In a way, HAB trackers have a fairly simple job: read sensors such as GPS and constantly relay that data to someone on the ground so that the balloon’s location can be tracked, and the hardware recovered when it ultimately returns to Earth. There are a lot of different ways to do this tracking, and one thing [Dave] enjoys is getting his hands on a new board and making a HAB tracker out of it. That’s exactly what he has done with the Raspberry Pi Pico.

Nothing builds familiarity like actually using a part, and the Pico had some useful things to contribute to a HAB tracker application. For one thing, the Pico has an onboard buck-boost converter that allows it to be powered from a relatively wide voltage range (~1.8 V to 5.5 V), so running it directly from batteries is both possible and desirable from a tracker perspective. But a really useful feature was possible thanks to the large amount of memory on the Pico: dynamic landing prediction.

[Dave] does landing prediction prior to launch based on environmental conditions, but it’s always better if the HAB tracker can also calculate its own prediction based on actual observed events and conditions. A typical microcontroller board like an Arduino doesn’t have enough memory to store the required data upon which to do such calculations, but the Pico does so easily. [Dave]’s new board transmits an updated landing site prediction along with all the rest of the telemetry, making the retrieval process much more reliable.

Want to see a completely different approach to HAB recovery? Check out a payload guided by steerable parachutes.