Alan Turing’s Remarkable, Nearly-Forgotten Voice Encryption Device

[Popular Mechanics] has an interesting article about Alan Turing’s nearly-forgotten speech encryption device. Codenamed Delilah, it was in many ways an early form of digital encryption. It was secretly developed alongside his most famous wartime achievement of breaking the encryption used by the Nazis’ Enigma machine; itself a remarkable device we’ve covered in detail in the past.

Delilah was developed at a separate location, and Turing worked with a young electrical engineer by the name of Donald Bayley who not only helped Turing implement design concepts and theory as practical circuitry, but took copious notes of their work and discussions. His documents went up for auction in 2023, a few years after his death, and they reveal a first-hand account of their work.

SIGSALY (the name is not an acronym, by the way) was a working voice encryption system whose main drawbacks were its massive size, weight, and power requirements. [image: Wikipedia]
Back then, a vocal encryption system did exist. Bell Labs had developed SIGSALY, a seriously top-secret system that provided encrypted voice communications at the highest levels. But one of SIGSALY’s biggest drawbacks was that it was absolutely monstrous.

Delilah did the same job, but was portable and battery-powered. Delilah was three small boxes weighing around 39 kg, and it’s hard to overstate just how remarkable of a feat of miniaturization this was. However, by the time Delilah was wrapped up, the war was over and the project wound down without ever being produced or deployed in any meaningful way.

Encrypted communications is standard stuff today, but back then there was simply no need for a vocal encryption system in peacetime. The reason we know what we do today is thanks mainly to the effort Bayley put into documenting things. It’s yet another achievement by a man for whom life was far from being either easy or fair; Turing was prosecuted by his own government for “homosexual acts” and ultimately took his own life in the years following the war.

It again demonstrates that if the people involved don’t write things down while they know it, that knowledge can simply disappear. Sometimes people make the effort and the rest of us benefit, like with the Delilah project and also with the history of liquid rocket propellants — a dry-sounding topic that we assure you is anything but.

All The Different Lasers, And How Well They Mark 3D Prints

[Stefan] of CNC Kitchen has an informative video describing his experiences with trying to cleanly laser-mark 3D printed plastics using different methods, and it also happens to be a fantastic tour of all the different laser options available to hobbyists and workshops these days.

Laser marking is a fast and effective way to put things like product names, serial numbers, and other information on plastics. [Stefan] wondered whether laser options would be capable of creating clean and professional marks on 3D-printed items, and approached things with his usual attention to detail.

Continue reading “All The Different Lasers, And How Well They Mark 3D Prints” →

Bike-Powered Shredder Makes Short Work Of 3D Printer Waste

[Brogan M Pratt] and his students do a lot of 3D printing, and as such found themselves producing a lot of plastic waste. Seeing an opportunity, they built a bike-powered plastic shredder that turns a little human exercise into the power needed to transform waste plastic into small bits. Shredding plastic is a necessary first step for any sort of processing, so getting this part working reliably is as important as it is educational.

Shredding is a necessary first step to processing plastic waste.

Being in the Netherlands, using a bike makes perfect sense. But it turns out there’s a lot more to making a human-powered plastic shredder than simply bolting a sprocket to a shredder, looping the bike chain over it, then climbing on and working up a sweat.

In between the bike and the shredder is a large gear reduction, a fifteen kilogram flywheel, and a heavy-duty frame to anchor everything in the face of so much mass and torque. Add some covers and safety guards and the result is a stationary bike with a hopper for waste, a bin for output, and enough rotational torque and inertia to chew through stubborn bits without stalling.

Now that the shredder works, what’s the plan for all the little plastic shreds? The goal is to turn it back into usable filament which is obviously very useful, but we’ve also seen that compression molding plastic waste can work pretty well, too.

Being an educator, [Brogan] makes it clear that a bike-powered shredder, while pretty cool, is not the only missing link in sustainability. There is currently no easy way to recycle plastic at scale. But the shredder is a critical part of demonstrating the whole process in a hands-on way, and learning why recycling plastic at scale is a genuinely difficult job.

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Ergonomic Mouse Gives Each Fingertip Its Own Saddle

Want to make your own ergonomic mouse but don’t know where to start? Why not try [psudoku]’s Kotinos design?

It’s a scaffold-like fingertip shell that uses the internals of an HSK Pro mouse. Each fingertip gets its own little saddle-shaped nook, and things like hand size and paddle surface can all be configured by modifying the OpenSCAD scripts.

[psudoku]’s unit looks to us as though it was maybe made using multi-jet fusion (MJF) 3D printing, but it should be perfectly printable on hobbyist printers, whether resin- or filament-based.

Comfort of the contact surfaces is left up to the end user, but if your print lacks smoothness and sanding isn’t your jam, you might consider a layer of fabric tape to create a velvet-like surface on a 3D print. That’s a trick we’ve kept in mind ever since seeing it put to good use, cushioning the hardware in a DIY steam deck case.

Is the minimalist scaffold approach to a mouse not your style, or does your hand crave something less lightweight but a little more personalized? You might want to craft a truly custom-fitted mouse, for which clay is the way.

Downloadable Xbox Thumbstick Toppers Give Gamers Accessibility Options

Microsoft has a history of taking accessibility options seriously for gaming controllers, and that trend continues with downloadable thumbstick toppers for Xbox controllers. Being straight from the source, the 3D models should fit as well as can be expected with a minimum of fiddling. Just make sure you select the right controller model, because they are each subtly different.

The toppers themselves come in different styles, and there’s a design to fit a variety of needs, from a thumb cradle to ones intended for more serious adaptations —  the perforated X-shaped topper, for instance, is meant to anchor a custom shape molded overtop it.

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IKEA Storage Box Just Happens To Make Great Printer Cover

The Snapmaker U1 3D printer is an impressive machine for the price, but [Beaver Works] found the optional factory-offered top cover a wee bit expensive for his tastes. The solution? 3D print a fixture and use a clear 45 L Samla storage box from IKEA as an effective and affordable cover for the machine.

Why a cover?  A cover helps retain heat and block drafts, which can help improve print quality. A cover also keeps the machine’s insides dust and debris-free, not to mention serving as a decent barrier to curious fingers or paws.

This is a great use of an off-the-shelf product that performs at least as well as any bespoke solution. The nature of printer enclosures makes them trickier than one might think, with the size and weight of materials often driving costs up for something that seems relatively simple in concept. Getting one by 3D printing the fixtures and purchasing the bulky part locally and affordably is a great alternative. IKEA even sells the box’s lid separately, so one can buy just the box and isn’t stuck with an unused lid afterward.

Integrating off-the-shelf components into a design is often risky because much of it is outside the designer’s control. Availability can change, and a manufacturer might alter dimensions or design elements without any notice. But IKEA’s storage products are pretty well standardized and work really well for this purpose.

On the off chance you need a design tweak, [Beaver Works] has provided STEP files for the 3D-printed parts, something we always love to see.

Bambuddy Says Bye To Bambu Lab Cloud Services

If you have a Bambu Labs printer and aren’t keen to send your files to Bambu’s servers with each print job, then check out Bambuddy, an open-source, self-hosted, cloud-free central command that offers a local alternative for managing Bambu Labs printers. It acts as a replacement for the official cloud services, allowing you to slice, print, and monitor with full local control and zero reliance on Bambu Labs’ servers. Continue reading “Bambuddy Says Bye To Bambu Lab Cloud Services” →