Fail Of The Week: In CAD, Remember To Model The Environment

March 31, 2020 by Donald Papp 51 Comments

What’s wrong with the above picture? Failure can be an excellent teacher, and [J. Peterson] reminds us all of this when he says to remember to model the environment when designing things in CAD. He contrasts a failure with a success to demonstrate what that means.

The failure was a stand for a screwdriver set, shown above. He modeled up a simple stand to hold a screwdriver handle and the bits in a nice, tight formation. He didn’t model any of parts, he just took some measurements and designed the holder. Everything fit just fine, but it had a major ergonomic problem: you can barely reach the handle because it is fenced in by the surrounding bits! Had he modeled all of the parts during the design phase, and not just the part he was making, this problem would have been immediately obvious during the design phase.

The contrasting success is an adapter he designed to mount an artistic glass marble to a lit display stand. The stand itself as well as the glass marble were modeled in CAD, then the adapter designed afterwards to fit them. With all of the involved objects modeled, he could be certain of how everything fit together and it worked the first time.

Now, to most people with a 3D printer of their own, discovering a part isn’t quite right is not a big (nor even a particularly expensive) problem to have, but that’s not the point. Waste and rework should be avoided if possible. To help do that, it can be good to remember to model the whole environment, not just the thing being made. Add it on to the pile of great design advice we’ve seen for designing things like enclosures and interfaces.

Teardown Of Costco Ceiling Light Reveals Microwave Motion Sensor And Hackable Design

March 30, 2020 by Donald Papp 18 Comments

[hclxing] eagerly picked up an LED ceiling light for its ability to be turned on and off remotely, but it turns out that the lamp has quite a few other features. These include adjustable brightness, color temperature, automatic turnoff, light sensing, motion sensing, and more. Before installing, [hclxing] decided to tear it down to see what was involved in bringing all those features to bear, but after opening the lamp there wasn’t much to see. Surprisingly, besides a PCB laden with LEDs, there were exactly two components inside the unit: an AC power adapter and a small white controller unit. That’s it.

Microwave-based motion sensor board on top, controller board for LED ceiling light underneath.

The power adapter is straightforward in that it accepts 100-240 Volts AC and turns it into 30-40 Volts DC for the LEDs, and it appears to provide 5 V for the controller as well. But [hclxing] noticed that the small white controller unit — the only other component besides the LEDs — had an FCC ID on it. A quick bit of online sleuthing revealed that ID is attached to a microwave sensor module. Most of us would probably expect to see a PIR sensor, but this light is motion sensing with microwaves. We have seen such units tested in the past, which links to a video [hclxing] also references.

The microwave motion sensor board is shown here, and underneath it is a dense PCB that controls all other functions. Once [hclxing] identified the wires and their signals, it was off to Costco to buy more because the device looks eminently hackable. We’re sure [hclxing] can do it, given their past history with reverse-engineering WyzeSense hardware.

How To Try Generative Optimization At Home

March 29, 2020 by Donald Papp 29 Comments

Chairs, spokes on a wheel, bridges, and all kinds of other load-bearing objects are designed such that material is only present where it is needed. There’s a process by which the decisions about how much material to put and where is determined by computer, and illustrating this is [Adam Bender]’s short primer on how to use generative optimization in Autodesk’s Fusion 360 (which offers a variety of free licenses) using a wheel as an example.

Things start with a solid object and a definition of the structural loads expected. The computer then simulates the force (or forces) involved, and that simulation can be used to define a part that only has material where it’s really needed. The results can be oddly organic looking, and this process has been used to optimize spacebound equipment where every gram counts.

It’s far from an automated process, but it doesn’t look too difficult to navigate the tools for straightforward designs. [Adam] cautions that one should always be mindful of the method of manufacturing when designing the part’s final form, which is always good advice but especially true when making oddball shapes and curves. To see the short process in action, watch the video embedded below.

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Can Solder Paste Stencils Be 3D Printed? They Can!

March 27, 2020 by Donald Papp 37 Comments

3D printed solder paste stencil, closeup.

[Jan Mrázek]’s success with 3D printing a solder paste stencil is awfully interesting, though he makes it clear that it is only a proof of concept. There are a lot of parts to this hack, so let’s step through them one at a time.

First of all, it turns out that converting a PCB solder paste layer into a 3D model is a bit of a challenge. A tool [Jan] found online didn’t work out, so he turned to OpenSCAD and wrote a script (available on GitHub) which takes two DXF files as input: one for the board outline, and one for the hole pattern. If you’re using KiCad, he has a Python script (also on GitHub) which will export the necessary data.

The result is a 3D model that is like a solder paste mask combined with a raised border to match the board outline, so that the whole thing self-aligns by fitting on top of the PCB. A handy feature, for sure. [Jan] says the model pictured here printed in less than 10 minutes. Workflow-wise, that certainly compares favorably to waiting for a stencil to arrive in the mail. But how do the actual solder-pasting results compare?

3D printed solder stencil on PCB, after applying solder paste.

[Jan] says that the printed stencil had a few defects but it otherwise worked fine for 0.5 mm pitch ICs and 0402 resistors, and the fact that the 3D printed stencil self-registered onto the board was a welcome feature. That being said, it took a lot of work to get such results. [Jan]’s SLA printer is an Elegoo Mars, and he wasn’t able to have it create holes for 0.2 mm x 0.5 mm pads without first modifying his printer for better X/Y accuracy.

In the end, he admits that while a functional DIY solder stencil can be 3D printed in about 10 minutes, it’s not as though professionally-made stencils that give better results are particularly expensive or hard to get. Still, it’s a neat trick that could come in handy. Also, a quick reminder that we stepped through how to make a part in OpenSCAD in the past, which should help folks new to OpenSCAD make sense of [Jan]’s script.

The Fart Box, A Synthesizer Not Quite Like Others

March 21, 2020 by Donald Papp 20 Comments

[lookmumnocomputer] enjoys creating synthesizers, and early last year he created one called The Fart Box. It is an entirely analog synthesizer with which, according to its creator, it is difficult to make anything that doesn’t sound gassy. It’s not quite like any other synthesizer, and while it is capable of acting like a regular analog synth it is never very far from cranking out farty sounds.

One may think this is just a gimmick, but it can actually be quite musical. There’s a good demonstration at the 7:09 mark in the video of what it can do. Entirely hand-made, it’s definitely a labor of love. There’s a bill of materials and a wiring diagram (of a sort) for anyone who is interested in such details, but it looks like it was a limited run only. [lookmumnocomputer]’s whole video is embedded below, and he demonstrates its ability to act more like a “normal” synthesizer around 8:30.

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Used Soda Stream Cylinder Becomes DIY Canned Air

March 17, 2020 by Donald Papp 16 Comments

Soda Stream machines use a cylinder of compressed CO2 to carbonate beverages, and cylinders that are “empty” for the machine’s purposes in fact still have a small amount of gas left in them. User [Graldur] shared a clever design for using up those last gasps from a cylinder by turning it into a makeshift compressed air gun, the kind that can blow crumbs or dust out of inconvenient spots like the inside of a keyboard. It’s 3D printed in PETG with a single seal printed in Ninjaflex.

[Graldur]’s 3D printed assembly screws onto the top of an “empty” cylinder and when the bottom ring is depressed like a trigger, the valve is opened slightly and the escaping gas is diverted through a narrow hole in the front. As a result, it can be used just as you would a can of compressed air. The gas outlet even accommodates the narrow plastic tubes from WD-40 cans (or disposable compressed air cans, for that matter) if more precision is required.

The design is intended for use with nearly-empty cylinders, but even so, [Graldur] also points out that it has been designed such that it can never fully actuate the cylinder’s release valve no matter how hard one presses, so don’t modify things carelessly. We also notice the design keeps the user’s hand and fingers well away from the business end of things.

This device also reminds of somewhat of a past experiment which used 3D printing to create serviceable (albeit low pressure) 3D printed compressed air tanks in custom shapes.

3D Printed Tooling Punches Above Its Weight With Added Hardware

March 9, 2020 by Donald Papp 18 Comments

Reddit user [thetelltalehart] has been making brake press tooling with 3D printed PLA, and recently shared an interesting picture of a hybrid brake press punch, shown here on the right, in blue.

Printed in PLA, with 80% infill and 12 walls, the tool (right) failed at 5 tons.

In a press, material such as sheet metal is formed into a shape by forcing the material around the tooling. Some types of tooling can be 3D printed, and it turns out that printed tools are not only fast and economical, but can be surprisingly resilient. You can see such tools in action in our earlier coverage of this approach here and here.

[Thetelltalehart]’s previous work was printed at 80% infill and 12 walls, and failed at 5 tons. The new hybrid tool adds some common hardware that has the effect of reinforcing the tool for very little added expense or complexity. The new tool made it up to 7 tons before failure. It’s a clever idea, and an apparently effective one.

The goal with these 3D printed tools is twofold: doing short-run work, and reducing costly rework when developing “real” tooling. Having to re-cut a tool because it isn’t quite right in some way is expensive and costly, and it’s much easier and cheaper to go through that process with 3D printing instead of metal.