Author: Dan Maloney

3288 Articles

Rolling Your Own Ball Screws

December 4, 2024 by 24 Comments

We’ve got mixed feelings about a new video from [AndysMachines] that details how he makes custom ball screws. On the one hand, there’s almost zero chance that we’ll ever have an opportunity to put this information to practical use. But on the other hand, the video gives a fantastic look at the inner workings and design considerations for ball screws, which is worth the price of admission alone

The story behind these ball screws is that [Andy] is apparently in cahoots with SkyNet and is building a T-800 Terminator of his own. Whatever, we don’t judge, but the build requires a short-throw linear drive mechanism that can be back-driven, specs that argue for a ball screw. [Andy] goes through the challenges of building such a thing, which mainly involve creating threads with a deep profile and wide pitch. The screw itself wasn’t too hard to cut, although there were some interesting practical details in the thread profile that we’d never heard of before.

The mating nut was another. Rather than try to cut deep internal threads, [Andy] took a sort of “open-face sandwich” approach, creating half-nuts in a single piece of brass using a CNC machine and a ball-nose mill. The threads were completed by cutting the two halves apart and bolting them together — very clever! [Andy] also showed how the balls recirculate in the nut through channels cut into one of the half-nuts.

Whether the results were worth the effort is up to [Andy], but we were just glad to be along for the ride. And if you want a little more detail on lead screws and ball screws, we’ve got just the article for that.

Continue reading “Rolling Your Own Ball Screws” →

Fail Of The Week: The SMD Crystal Radio That Wasn’t

December 3, 2024 by 18 Comments

The crystal radio is a time-honored build that sadly doesn’t get much traction anymore. Once a rite of passage for electronics hobbyists, the classic coil-on-an-oatmeal-carton and cat’s whisker design just isn’t that easy to pull off anymore, mainly because the BOM isn’t really something that you can just whistle up from DigiKey or Mouser.

Or is it? To push the crystal radio into the future a bit, [tsbrownie] tried to design a receiver around standard surface-mount inductors, and spoiler alert — it didn’t go so well. His starting point was a design using a hand-wound air-core coil, a germanium diode for a detector, and a variable capacitor that was probably scrapped from an old radio. The coil had three sections, so [tsbrownie] first estimated the inductance of each section and sourced some surface-mount inductors that were as close as possible to their values. This required putting standard value inductors in series and soldering taps into the correct places, but at best the SMD coil was only an approximation of the original air-core coil. Plugging the replacement coil into the crystal radio circuit was unsatisfying, to say the least. Only one AM station was heard, and then only barely. A few tweaks to the SMD coil improved the sensitivity of the receiver a bit, but still only brought in one very local station.

[tsbrownie] chalked up the failure to the lower efficiency of SMD inductors, but we’re not so sure about that. If memory serves, the windings in an SMD inductor are usually wrapped around a core that sits perpendicular to the PCB. If that’s true, then perhaps stacking the inductors rather than connecting them end-to-end would have worked better. We’d try that now if only we had one of those nice old variable caps. Still, hats off to [tsbrownie] for at least giving it a go.

Note: Right after we wrote this, a follow-up video popped up in our feed where [tsbrownie] tried exactly the modification we suggested, and it certainly improves performance, but in a weird way. The video is included below if you want to see the details.

Continue reading “Fail Of The Week: The SMD Crystal Radio That Wasn’t” →

Torque Testing 3D Printed Screws

December 3, 2024 by 18 Comments

Unless you’ve got a shop with a well-stocked hardware bin, it’s a trip to the hardware store when you need a special screw. But [Sanford Prime] has a different approach: he prints his hardware, at least for non-critical applications. Just how much abuse these plastic screws can withstand was an open question, though, until he did a little torque testing to find out.

To run the experiments, [Sanford]’s first stop was Harbor Freight, where he procured their cheapest digital torque adapter. The test fixture was similarly expedient — just a piece of wood with a hole drilled in it and a wrench holding a nut. The screws were FDM printed in PLA, ten in total, each identical in diameter, length, and thread pitch, but with differing wall thicknesses and gyroid infill percentages. Each was threaded into the captive nut and torqued with a 3/8″ ratchet wrench, with indicated torque at fastener failure recorded.

Perhaps unsurprisingly, overall strength was pretty low, amounting to only 11 inch-pounds (1.24 Nm) at the low end. The thicker the walls and the greater the infill percentage, the stronger the screws tended to be. The failures were almost universally in the threaded part of the fastener, with the exception being at the junction between the head and the shank of one screw. Since the screws were all printed vertically with their heads down on the print bed, all the failures were along the plane of printing. This prompted a separate test with a screw printed horizontally, which survived to a relatively whopping 145 in-lb, which is twice what the best of the other test group could manage.

[Sanford Prime] is careful to note that this is a rough experiment, and the results need to be taken with a large pinch of salt. There are plenty of sources of variability, not least of which is the fact that most of the measured torques were below the specified lower calibrated range for the torque tester used. Still, it’s a useful demonstration of the capabilities of 3D-printed threaded fasteners, and their limitations.

Continue reading “Torque Testing 3D Printed Screws” →

Modular Breadboard Snaps You Into Benchtop Tidiness

December 2, 2024 by 27 Comments

Solderless breadboards are a fantastic tool for stirring the creative juices. In a few seconds, you can go from idea to prototype without ever touching the soldering iron. Unfortunately, the downside to this is that projects tend to expand to occupy all the available space on the breadboard, and the bench surrounding the project universally ends up cluttered with power supplies, meters, jumpers, and parts you’ve swapped in and out of the circuit.

In an attempt to tame this runaway mess, [Raph] came up with this neat modular breadboard system. It hearkens back to the all-in-one prototyping systems we greatly coveted when the whole concept of solderless breadboards was new and correspondingly unaffordable. Even today, combination breadboard and power supply systems command a pretty penny, so rolling your own might make good financial sense. [Raph] made his system modular, with 3D-printed frames that lock together using clever dovetail slots. The prototyping area snaps to an instrumentation panel, which includes two different power supplies and a digital volt-amp meter. This helps keep the bench clean since you don’t need to string leads all over the place. The separate bin for organizing jumpers and tidbits that snaps into the frame is a nice touch, too.

Want to roll your own? Not a problem, as [Raph] has thoughtfully made all the build files available. What’s more, they’re parametric so you can customize them to the breadboards you already have. The only suggestion we have would be that making this compatible with [Zack Freedman]’s Gridfinity system might be kind of cool, too.

Unique 3D Printer Has A Print Head With A Twist

December 2, 2024 by 26 Comments

If you’re used to thinking about 3D printing in Cartesian terms, prepare your brain for a bit of a twist with [Joshua Bird]’s 4-axis 3D printer that’s not quite like anything we’ve ever seen before.

The printer uses a rotary platform as a build plate, and has a linear rail and lead screw just outside the rim of the platform that serves as the Z axis. Where things get really interesting is the assembly that rides on the Z-axis, which [Joshua] calls a “Core R-Theta” mechanism. It’s an apt description, since as in a CoreXY motion system, it uses a pair of stepper motors and a continuous timing belt to achieve two axes of movement. However, rather than two linear axes, the motors can team up to move the whole print arm in and out along the radius of the build platform while also rotating the print head through almost 90 degrees.

The kinematic possibilities with this setup are really interesting. With the print head rotated perpendicular to the bed, it acts like a simple polar printer. But tilting the head allows you to print steep overhangs with no supports. [Joshua] printed a simple propeller as a demo, with the hub printed more or less traditionally while the blades are added with the head at steeper and steeper angles. As you can imagine, slicing is a bit of a mind-bender, and there are some practical problems such as print cooling, which [Joshua] addresses by piping in compressed air. You’ll want to see this in action, so check out the video below.

This is a fantastic bit of work, and hats off to [Joshua] for working through all the complexities to bring us the first really new thing we’ve seen in 3D printing is a long time.

Continue reading “Unique 3D Printer Has A Print Head With A Twist” →

Homebrew Phosphorescence Detector Looks For The Glow In Everyday Objects

November 28, 2024 by 8 Comments

Spoiler alert: almond butter isn’t phosphorescent. But powdered milk is, at least to the limit of detection of this homebrew phosphorescence detector.

Why spend a bunch of time and money on such a thing? The obvious answer is “Why not?”, but more specifically, when [lcamtuf]’s son took a shine (lol) to making phosphorescent compounds, it just seemed natural for dad to tag along in his own way. The basic concept of the detector is to build a light-tight test chamber that can be periodically and briefly flooded with UV light, charging up the putatively phosphorescent compounds within. A high-speed photodiode is then used to detect the afterglow, which can be quantified and displayed.

The analog end of the circuit was the far fussier end of the design, with a high-speed transimpedance amplifier to provide the needed current gain. Another scaling amp and a low-pass filter boosts and cleans up the signal for a 14-bit ADC. [lcamtuf] went to great lengths to make the front end as low-noise as possible, including ferrite beads and short leads to prevent picking up RF interference. The digital side has an AVR microcontroller that talks to the ADC and runs an LCD panel, plus switches the 340 nm LEDs on and off rapidly via a low gate capacitance MOSFET.

Unfortunately, not many things found randomly around the average home are all that phosphorescent. We’re not sure what [lcamtuf] tried other than the aforementioned foodstuffs, but we’d have thought something like table salt would do the trick, at least the iodized stuff. But no matter, the lessons learned along the way were worth the trip.

A Look Under The Hood Of Intermediate Frequency Transformers

November 27, 2024 by 11 Comments

If you’ve been tearing electronic devices apart for long enough, you’ll know that the old gear had just as many mysteries within as the newer stuff. The parts back then were bigger, of course, but often just as inscrutable as the SMD parts that populate boards today. And the one part that always baffled us back in the days of transistor radios and personal cassette players was those little silver boxes with a hole in the top and the colorful plug with an inviting screwdriver slot.

We’re talking about subminiature intermediate-frequency transformers, of course, and while we knew their purpose in general terms back then and never to fiddle with them, we never really bothered to look inside one. This teardown of various IF transformers by [Unrelated Activities] makes up somewhat for that shameful lack of curiosity. The video lacks narration, relying on captions to get the point across that these once-ubiquitous components were a pretty diverse lot despite their outward similarities. Most had a metal shell protecting a form around which one or more coils of fine magnet wire were wrapped. Some had tiny capacitors wired in parallel with one of the coils, too.

Perhaps the most obvious feature of these IF transformers was their tunability, thanks to a ferrite cup or slug around the central core and coils. The threaded slug allowed the inductance of the system to be changed with the turn of a screwdriver, preferably a plastic one. [Unrelated] demonstrates this with a NanoVNA using a nominal 10.7-MHz IFT, probably from an FM receiver. The transformer was tunable over a 4-MHz range.

Sure, IFTs like these are still made, and they’re not that hard to find if you know where to look. But they are certainly less common than they used to be, and seeing what’s under the hood scratches an itch we didn’t even realize we had.

Continue reading “A Look Under The Hood Of Intermediate Frequency Transformers” →