“Smilemachine” Helmet Is A Delightful Mixture Of Tech

September 19, 2016 by Donald Papp 13 Comments

Part performance art and part social experiment, [mocymo]’s Smilemachine V6 helmet is as delightful as it is expressive. The helmet is made primarily from laser-cut MDF assembled around parts from a safety helmet. The display is an Android tablet with fine operation controlled by a Bluetooth mini keyboard, and the helmet cleverly makes use of the tablet’s ability to adjust the display to compensate for head tilt angle. It recently made an appearance at Maker Faire Tokyo, where the creator says the reception (especially by children) exceeded expectations.

There are several interesting things done with this device. One is the handheld controller, which is essentially a mini Bluetooth keyboard. To help allow fine control without needing to look down at the controller, the keyboard sits in a frame with some nuts and bolts used as highly tactile button extensions. By allowing the user to change the physical button layout (and setting up keyboard shortcuts on the device to match) the arrangement can be made more intuitive for the user. Some photos of this assembly are in the gallery after the break.

smilemachine-periscope — Geared mirrors to allow seeing out the front of the helmet.

Another interesting bit is that despite a tablet being right in front of your eyes, it is possible to see out the front of the helmet while wearing it. The solution is completely low-tech: two mirrors form a periscope whose angle can be adjusted by turning a knob on the side of the helmet.

Version 1 of the helmet was started back in 2012; this is version 6 and [mocymo] is already filling out a to-do list for refinements. The nose area is uncomfortable, the angle of periscope is slightly off and the gearing needs to be reworked, among other things. We can’t wait to see Version 7. Video and gallery are embedded below.

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3D Printed Door Latch Has One Moving Part – Itself!

September 14, 2016 by Donald Papp 31 Comments

A group at the Hasso-Plattner Institute in Germany explored a curious idea: using 3D printed material not just as a material – but as a machine in itself. What does this mean? The clearest example is the one-piece door handle and latch, 3D printed on an Ultimaker 2 with pink Ninjaflex. It is fully functional but has no moving parts (besides itself) and has no assemblies. In other words, the material itself is also the mechanism.

The video (embedded below) showcases some similar concept pieces: door hinges, a pair of pliers, a pair of walker legs, and a pantograph round out the bunch. Clearly the objects aren’t designed with durability or practicality in mind – the “pliers” in particular seem a little absurd – but they do demonstrate different takes on the idea of using a one-piece item’s material properties as a functional machine in itself.

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Complex, Beautiful Device Is Limited To Text-speak And Cat Pictures (WTF, LOL)

September 13, 2016 by Donald Papp 27 Comments

Beautifully documented, modular, and completely open-source, this split flap display project by [JON-A-TRON] uses 3D printing, laser cutting and engraving, and parts anyone can find online to make a device that looks as sharp as it is brilliantly designed. Also, it appears to be a commentary on our modern culture since this beautifully engineered, highly complex device is limited to communicating via three-letter combos and cat pictures (or cat video, if you hold the button down!) As [JON-A-TRON] puts it, “Why use high-resolution, multi-functional devices when you can get back to your industrial revolution roots?” Video is embedded below.

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Super-small Robotic Joints Don’t Exist? They Do Now!

September 12, 2016 by Donald Papp 11 Comments

[Tim] needed very small, motorized joints for a robot. Unable to find anything to fit the bill, he designed his own tiny, robotic joints. Not only are these articulated and motorized, they are designed to be independent – each containing their own driver and microcontroller.

6mm geared motor next to LEGO [Source: Pololu]

None of the photos or video really give a good sense of just how small [Tim]’s design is. The motor (purple in the 3D render above, and pictured to the left) is a sub-micro planetary geared motor with a D shaped shaft. It is 6mm in diameter and 19mm long. One of these motors is almost entirely encapsulated within the screw it drives (green), forming a type of worm gear. As the motor turns the screw, a threaded ring moves up or down – which in turn moves the articulated shaft attached to the joint. A video is embedded below that shows the joint in action.

[Tim] originally tried 3D printing the pieces on his Lulzbot but it wasn’t up to the task. He’s currently using a Form 2 with white resin, which is able to make the tiny pieces just the way he needs them.

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Careful Crafting Makes DIY 7-Segment Display Shine

September 10, 2016 by Donald Papp 5 Comments

[MattB] decided to go the DIY route for some 7 segment displays that were several inches tall, but he had some particular requirements. He wanted precisely shaped elements that were as cleanly and evenly lit as possible, with no obvious points of illumination from LEDs and no visibly uneven edge lighting. To do this, he used the tools and materials he had on hand and carefully handcrafted each segment. The result is awfully close to his ideal!

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Safely Remove Drill Chuck; Receive Motor, Gearbox, And Clutch

September 8, 2016 by Donald Papp 34 Comments

There’s a treasure trove of usefulness inside of an electric drill. [Steven Dufresne], Hackaday writer and the mad scientist behind Rimstar.org, kindly documented how to safely and reliably remove the chuck from a drill motor. You may think this is easy, but once in a while you’ll come across a drill determined to hold onto all its bits. We certainly were entertained by the lengths [Steven] went to in the video below to get a Black and Decker to give up its chuck.

An understanding of how the chuck and gearbox are connected, combined with the right tools and a bit of force, gets you a motor, gears and gearbox, and a clutch. There’s not much left in the drill after that, and you can put some or all of those components to new use — like using them for the drive system of a BB-8 Droid.

Many projects (like this walking scooter) make use of cordless drills as motor sources. Being able to skip the chuck in order to interface directly to the shaft is useful for those projects where the drill is at least a semi-permanent part of the build. Ask your friends, neighbors, and at work. Cheap cordless drills and screw guns have been around for a long time. It’s usually the batteries that go and many people have the drills lying around and will be happy to part with them knowing you’re going to do something awesome with them.

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Amazing Meccano Pinball Machine Fully Functional Before Meeting Its Fate

September 7, 2016 by Donald Papp 40 Comments

[Brian Leach] of the South East London Meccano Club has put an impressive amount of ingenuity into making his pinball machine almost entirely out of Meccano parts. He started in 2013 and we saw an earlier version of the table back in 2014, but it has finally been completed. It has all the trappings of proper pinball: score counter, score multiplier with timeout, standing targets, kickouts, pot bumpers, drop targets, and (of course) flippers and plunger.

The video (embedded below) is very well produced with excellent closeups of the different mechanisms as [Brian] gives a concise tour of the machine. Some elements are relatively straightforward, others required workarounds to get the right operation, but it’s all beautifully done. For example, look at the score counter below. Meccano electromagnets are too weak to drive the numbers directly, so a motor turns all numbers continuously with a friction drive and electromagnets are used to stop the rotation at specific points. Reset consists of letting the numbers spin freely to 9999 then doing a last little push for a clean rollover to zero.