Author: Dan Maloney

3368 Articles

Hackaday Podcast 171: Rent The Apple Toolkit, DIY An Industrial CNC, Or Save The Birds With 3D Printing

June 3, 2022 by 4 Comments

Join Hackaday Editor-in-Chief Elliot Williams and Staff Writer Dan Maloney for a tour of the week’s best and brightest hacks. We begin with a call for point-of-sale diversity, because who wants to carry cash? We move on to discussing glass as a building material, which isn’t really easy, but at least it can be sintered with a DIY-grade laser. Want to make a call on a pay phone in New York City? Too late — the last one is gone, and we offer a qualified “good riddance.” We look at socially engineering birds to get them away from what they should be really afraid of, discuss Apple’s potential malicious compliance with right-to-repair, and get the skinny on an absolute unit of a CNC machine. Watching TV? That’s so 2000s, but streaming doesn’t feel quite right either. Then again, anything you watch on a mechanical color TV is pretty cool by definition.

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A Rotocasting Machine Sized For The Home Shop

June 3, 2022 by 5 Comments

If you’ve ever wondered how large, hollow plastic structures like tanks and drums are formed, you’re in luck: [Andy] not only fills us in on the details of rotational casting and molding, but he also built this sweet little rotational casting machine to help him with his DIY projects.

Granted, [Andy]’s build won’t be making anything too large, like a car fuel tank or a kayak. Not only is it sized more for smallish parts, but those structures are generally made with the related process of rotational molding. Both processes use an enclosed multipart mold that’s partially filled with plastic resin, and then rotate the mold around two axes to distribute a thin layer of resin around the inside of the mold. The difference is that roto-molding uses a thermoplastic resin, whereas roto-casting uses resins like polyurethane and silicone that set at room temperature.

The machine looks simple, but only because he took great pains to optimize it. The videos below cover the build in detail — feel free to skip to the 11:38 mark of the second video if you just want to see it in action. Though you’ll be missing some juicy tidbits, like welding a perfect 90° joint in square tubing. There’s also the custom tool [Andy] built to splice the beaded chain he used to drive the spinning of the mold, which was pure genius.

Using the machine and a complex nine-piece mold, [Andy] was able to create remarkably detailed tires for RC cars from polyurethane resin. We’d love to see what else this rig is good for — almost as much as we want to see details on how the mold was made. We’ve seen other rotational casting machines before, but this one takes the cake for fit and finish.

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Retrotechtacular: Clay Pipe The Hard Way

May 31, 2022 by 28 Comments

Troll YouTube long enough and chances are good that you’ll come across all kinds of videos of the “How It’s Made” genre. And buried in with the frying pans and treadmills and dental floss manufacturers, there no doubt will be deep dives on how pipe is made. Methods will vary by material, but copper, PVC, cast iron, or even concrete, what the pipe factories will all have in common is the high degree of automation they employ. With a commodity item like pipe, it’s hard to differentiate yourself from another manufacturer on features, so price is about the only way to compete. That means cutting costs to the bone, and that means getting rid of as many employees as possible.

Such was not always the case, of course, as this look at how Irish Stoneware & Fireclays Ltd. made clay pipe, drain tiles, and chimney flues back in the 1980s shows. The amount of handwork involved in making a single, simple piece of clay pipe is astonishing, as is the number of hands employed at the various tasks. The factory was located in Carrickmacross, County Monaghan, Ireland, near an outcropping of shale that forms the raw material for its products. Quarrying the shale and milling it into clay were among the few mechanized steps in the process; although the extrusion of the pipe itself was also mechanized, the machines required teams of workers to load and unload them.

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Hackaday Links: May 29, 2022

May 29, 2022 by 15 Comments

It looks like the ongoing semiconductor shortage isn’t getting any better, and if the recent spate of computer thefts from semi trucks is any indication, it’s only going to get worse. Thieves seem to be targeting the Freightliner Cascadia, probably the most popular heavy freight truck on the road in North America today, with “smash and grab” thefts targeting the CPC4, or Common Powertrain Control module. These modules are sitting ducks — they’re easy to locate and remove, the chip shortage has made legit modules nearly unobtanium from dealers, and the truck won’t run without them. That’s driven the black market price for a CPC up to $8,000 or more, making them a tempting target. And it’s not only individual trucks parked in truck stop lots that are being hit; gangs are breaking into trucking company lots and bricking dozens of trucks in short order. So the supply chain problem which started the semiconductor shortage caused the module shortage, which drives the thieves to steal modules and take trucks off the road, which only worsens the supply chain shortage that started the whole thing. Nice positive feedback loop.

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Relax And Enjoy This Simple Drone Synthesizer

May 29, 2022 by 2 Comments

You’d think that a synthesizer that makes as much noise and sports as many knobs as this one would have more than a dozen transistors on board. Surely the circuit behind the panel is complex, and there must be at least a couple of 555 timers back there, right?

But no, the “Box of Beezz” that [lonesoulsurfer] came up with is remarkably simple. It takes inspiration from a [Look Mum No Computer] circuit called the “Circle Drone of Doom,” which used six switchable relaxation oscillators to make some pretty cool sounds. The Box of Beezz steps that up a bit, with four oscillators in three switchable banks in the final version. Each oscillator has but one transistor with a floating base connection and a simple RC network on the collector. The sawtooth outputs of these relaxation oscillators can be adjusted and summed together, resulting in some surprisingly complex sounds. Check out the video below for a bit of the synth’s repertoire — we’d swear that there are points where we can hear elements of the THX Deep Note in there.

We poked around a bit to understand these oscillators, and it looks like these qualify as avalanche relaxation oscillators. [lonesolesurfer]’s notes indicate that SS9018 transistors should be used, but in the photos they appear to all be 2N4401s. We’re not sure how long the transistors will last operating in the avalanche mode, but if they quit, maybe some neon tubes would work instead.

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Upcycled Practice Amp Build Goes To Eleven

May 26, 2022 by 19 Comments

What do you call someone who gives the toddler in your life a musical instrument as a gift? In most cases, “mortal enemy” is the correct answer, but not everyone feels quite so curmudgeonly, and might even attempt to turn up the volume a bit. Such is the case with this wonderfully detailed practice amp for the grandkids’ electric ukelele.

The aptly named [packrat] [Professor Mayhem] really made this build a tour de force of scrap bin sourcing. The amp is built around a module salvaged from an old TV, a stereo Class-D amp that was modified to provide 30 watts output and a volume control. The driver came from a flood-damaged speaker unit, and the power supply from a gutted wall wart. The case was built with scrap plywood and covered with pebble-grain fabric to give it that pro audio look, while the chassis for the electronics was bent from a piece of sheet steel.

But it’s the tiny details that really sell this project. Everything from the pilot light to the pointer knob screams 1970s, as do the painstaking front panel lettering and vinyl “Monkeydyne” logo. [Professor Mayhem] even went the extra mile to create an etched-brass serial number plate, a mock specs and safety label, and even a QA inspection tag that was (sort of) stapled inside the cabinet.

We tip our hats to [Professor Mayhem] for this four-month labor of love and obvious nostalgia trip, which the kids are sure to love. [Professor Mayhem] does admit that some will argue with his decision to use a Class D amp and a switch-mode power supply, but let’s be real — for the application, it’s probably more than sufficient.

Thanks for the tip, [packrat].

Homebrew Radio Telescope Bags Pulsar

May 25, 2022 by 11 Comments

When one mulls the possibility of detecting pulsars, to the degree that one does, thoughts turn to large dish antennas and rack upon rack of sensitive receivers, filters, and digital signal processors. But there’s more than one way to catch the regular radio bursts from these celestial beacons, and if you know what you’re doing, a small satellite dish and an RTL-SDR dongle will suffice.

Granted, [Job Geheniau] has had a lot of experience exploring the radio universe. His website has a long list of observations and accomplishments achieved using his “JRT”, or “Job’s Radio Telescope.” The instrument looks like a homebrewer’s dream, with a 1.9-m satellite TV dish and precision azimuth-elevation rotator. Behind the feedhorn are a pair of low-noise amplifiers and bandpass filters to massage the 1,420 MHz signal that’s commonly used for radio astronomy, plus a Nooelec Smart SDR dongle and an Airspy Mini. Everything is run via remote control, as the interference is much lower with the antenna situated at his family’s farm, 50 km distant from his home in The Hague.

As for the pulsar, bloodlessly named PSR B0329+54, it’s a 5-million-year-old neutron star located in the constellation of Camelopardalis, about 3,500 light-years away. It’s a well-characterized pulsar and pulses at a regular 0.71452 seconds, but it’s generally observed with much, much larger antennas. [Job]’s write-up of the observation contains a lot of detail on the methods and software he used, and while the data is far from clear to the casual observer, it sure seems like he bagged it.

We’ve seen quite a few DIY radio astronomy projects before, both large and small, but this one really impresses with what it accomplished.

[via RTL-SDR.com]