Author: Dan Maloney

3373 Articles

SLA printer rigged for time lapse

Silky Smooth Resin Printer Timelapses Thanks To Machine Vision

September 18, 2021 by 19 Comments

The fascination of watching a 3D printer go through its paces does tend to wear off after you spent a few hours doing it, in which case those cool time-lapse videos come in handy. Trouble is they tend to look choppy and unpleasant unless the exposures are synchronized to the motion of the gantry. That’s easy enough to do on FDM printers, but resin printers are another thing altogether.

Or are they? [Alex] found a way to make gorgeous time-lapse videos of resin printers that have to be seen to be believed. The advantage of his method is that it’ll work with any camera and requires no hardware other than a little LED throwie attached to the build platform of the printer. The LED acts as a fiducial that OpenCV can easily find in each frame, one that indicates the Z-axis position of the stage when the photo was taken. A Python program then sorts the frames, so it looks like the resin print is being pulled out of the vat in one smooth pull.

To smooth things out further, [Alex] also used frame interpolation to fill in the gaps where the build platform appears to jump between frames using real-time intermediate flow estimation, or RIFE. The details of that technique alone were worth the price of admission, and the results are spectacular. Alex kindly provides his code if you want to give this a whack; it’s almost worth buying a resin printer just to try.

Is there a resin printer in your future? If so, you might want to look over [Donald Papp]’s guide to the pros and cons of SLA compared to FDM printers.

Continue reading “Silky Smooth Resin Printer Timelapses Thanks To Machine Vision” →

A MetaSense joystick

3D-Printing Complex Sensors And Controls With Metamaterials

September 17, 2021 by 4 Comments

If you’ve got a mechatronic project in mind, a 3D printer can be a big help. Gears, levers, adapters, enclosures — if you can dream it up, a 3D printer can probably churn out a useful part for you. But what about more complicated parts, like sensors and user-input devices? Surely you’ll always be stuck buying stuff like that from a commercial supplier. Right?

Maybe not, if a new 3D-printed metamaterial method out of MIT gets any traction. The project is called “MetaSense” and seeks to make 3D-printed compliant structures that have built-in elements to sense their deformation. According to [Cedric Honnet], MetaSense structures are based on a grid of shear cells, printed from flexible filament. Some of the shear cells are simply structural, but some have opposing walls printed from a conductive filament material. These form a capacitor whose value changes as the distance between the plates and their orientation to each other change when the structure is deformed.

The video below shows some simple examples of monolithic MetaSense structures, like switches, accelerometers, and even a complete joystick, all printed with a multimaterial printer. Designing these structures is made easier by software that the MetaSense team developed which models the deformation of a structure and automatically selects the best location for conductive cells to be added. The full documentation for the project has some interesting future directions, including monolithic printed actuators.

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Angry antibodies

Monoclonal Antibodies: The Guided Missiles Of Medicine

September 15, 2021 by 11 Comments

Whenever anyone mentions the word “antibodies” these days, it’s sure to grab your attention. Thoughts generally flow to the human immune system and the role it plays in the ongoing COVID-19 pandemic, and to how our bodies fight off disease in general. The immune system is complex in the extreme, but pretty much everyone knows that antibodies are part of it and that they’re vital to the ability of the body to recognize and neutralize invaders like bacteria and viruses.

But as important as antibodies are to long-term immunity and the avoidance of disease, that’s far from all they’re good for. The incredible specificity of antibodies to their target antigens makes them powerful tools for biological research and clinical diagnostics, like rapid COVID-19 testing. The specificity of antibodies has also opened up therapeutic modalities that were once the stuff of science-fiction, where custom-built antibodies act like a guided missile to directly attack not only a specific protein in the body, but sometimes even a specific part of a protein.

Making these therapies work, though, requires special antibodies: monoclonal antibodies. These are very much in the news recently, not only as a possible treatment for COVID-19 but also to treat everything from rheumatoid arthritis to the very worst forms of cancer. But what exactly are monoclonal antibodies, how are they made, and how do they work?

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Hackaday Links Column Banner

Hackaday Links: September 12, 2021

September 12, 2021 by 7 Comments

The last thing an astronaut or cosmonaut on the International Space Stations wants to hear from one of their crewmates is, “Do you smell plastic burning?” But that’s apparently what happened this week aboard the increasingly problematic spacecraft, as the burning smell and visible smoke spread from the Russian Zvezda module to the American side of town. The reports say it occurred while charging the station’s batteries, and we all know how dicey that can get. But apparently, the situation resolved itself somehow, as normal operations continued soon after the event. Between reports of cracks, air leaks, problems with attitude control, and even accusations of sabotage, the ISS is really starting to show its age.

Speaking of burning and batteries, normally a story about burning Tesla batteries wouldn’t raise our eyebrows much. But this story out of California introduces a potential failure mode for Tesla batteries that we hadn’t considered before. It seems a semi-truck with a load of Tesla batteries lost its brakes on Interstate 80 in the Sierra Nevada mountains and ended up flipping across the highway. Video from the scene shows the cargo, which looks like replacement batteries or perhaps batteries salvaged from wrecked cars, scattered across the highway on their shipping pallets. A fire was reported, but it’s not clear whether it was one of the batteries which had gotten compromised in the crash, or if it was something other than the batteries. Still, we hadn’t considered the potential for disaster while shipping batteries like that.

Attention all GNURadio fans — GRCon21 is rapidly approaching. Unlike most of the conferences over the last year and half, GRCon21 will actually be both live and online. We always love the post-conference dump of talks, which cover such a wide range of topics and really dive deeply into so many cool areas. We’re especially looking forward to the SETI talks, and we’re pleased to see our friend Hash, who was on the Hack Chat a while back, scheduled to talk about his smart-meter hacking efforts. The conference starts on September 20 and is being held in Charlotte, North Carolina, and virtually of course. If you attend, make sure to drop tips to your favorite talks in the tips line so we can share them with everyone.

We got a tip this week on a video about how 1/4-wave tuning stubs work. It’s a simple demonstration using a length of coax, a signal generator, and an oscilloscope to show how an unterminated feedline can reflect RF back to the transmitter, and how that can be used to build super-simple notch filters and impedance transformers. We love demos that make the mysteries of RF a little simpler — W2AEW’s videos come to mind, like this one on standing waves.

Continue reading “Hackaday Links: September 12, 2021” →

Measuring current draw of home shop tools

Using Homebrew Coils To Measure Mains Current, And Taking The Circuit Breaker Challenge

September 12, 2021 by 21 Comments

Like many hackers, [Matthias Wandel] has a penchant for measuring the world around him, and quantifying the goings-on in his home is a bit of a hobby. And so when it came time to sense the current flowing in the wires of his house, he did what any of us would do: he built his own current sensing system.

What’s that you say? Any sane hacker would buy something like a Kill-a-Watt meter, or even perhaps use commercially available current transformers? Perhaps, but then one wouldn’t exactly be hacking, would one? [Matthias] opted to roll his own sensors for quite practical reasons: commercial meters don’t quite have the response time to catch the start-up spikes he was interested in seeing, and clamp-on current transformers require splitting the jacket on the nonmetallic cabling used in most residential wiring — doing so tends to run afoul of building codes. So his sensors were simply coils of wire shaped to fit the outside of the NM cable, with a bit of filtering to provide a cleaner signal in the high-noise environment of a lot of switch-mode power supplies.

Fed through an ADC board into a Raspberry Pi, [Matthias]’ sensor system did a surprisingly good job of catching the start-up surge of some tools around the shop. That led to the entertaining “Circuit Breaker Challenge” part of the video below, wherein we learn just what it really takes to pop the breaker on a 15-Amp branch circuit. Spoiler alert: it’s a lot.

Speaking of staying safe with mains current, we’ve covered a little bit about how circuit protection works before. If you need a deeper dive into circuit breakers, we’ve got that too.

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A flip-top foundry for metal casting

Flip-Top Foundry Helps Manage The Danger Of Metal Casting

September 11, 2021 by 18 Comments

Melting aluminum is actually pretty easy to do, which is why it’s such a popular metal for beginners at metal casting. Building a foundry that can melt aluminum safely is another matter entirely, and one that benefits from some of the thoughtful touches that [Andy] built into his new propane-powered furnace. (Video, embedded below.)

The concern for safety is not at all undue, for while aluminum melts at a temperature that’s reasonable for the home shop, it’s still a liquid metal that will find a way to hurt you if you give it half a chance. [Andy]’s design minimizes this risk primarily through the hands-off design of its lid. While most furnaces have a lid that requires the user to put his or her hands close to the raging inferno inside, or that dangerously changes the center of mass of the whole thing as it opens, this one has a fantastic pedal-operated lid that both lifts and twists. Leaving both hands free to handle tongs is a nice benefit of the design, too.

The furnace follows a lot of the design cues we’ve seen before, starting as it does with an empty party balloon helium tank. The lining is a hydrid of ceramic blanket material and refractory cement; another nice safety feature is the drain channel cast into the floor of the furnace in case of a cracked crucible. The furnace is also quite large, at least compared to [Andy]’s previous DIY unit, and has a sturdy base that aids stability — another plus in the safety column.

Every time we see a new furnace design, we get the itch to start getting into metal casting. And with the barrier to entry as low as a KFC bucket or an old fire extinguisher, why not give it a try? Although it certainly pays to know what can go wrong before diving in.

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An acousto-optic tunable filter and laser

Acousto-Optic Filter Uses Sound To Bend Light

September 10, 2021 by 17 Comments

We all know that light and sound are wave phenomena, but of very different kinds. Light is electromechanical in nature, while sound is mechanical. Light can travel through a vacuum, while sound needs some sort of medium to transmit it. So it would seem that it might be difficult to use sound to modify light, but with the right equipment, it’s actually pretty easy.

Easy, perhaps, if you’re used to slinging lasers around and terms like “acousto-optic tunable filter” fall trippingly from your tongue, as is the case for [Les Wright]. An AOTF is a device that takes a radio frequency input and applies it to a piezoelectric transducer that’s bonded to a crystal of tellurium oxide. The RF signal excites the transducer, which vibrates the TeO2 crystal and sets up a standing wave within it. The alternating bands of compressed and expanded material within the crystal act like a diffraction grating. Change the excitation frequency, and the filter’s frequency changes too.

To explore the way sound can bend light, [Les] picked up a commercial AOTF from the surplus market. Sadly, it didn’t come with the RF driver, but no matter — a few quick eBay purchases put the needed RF generator and power amplifier on his bench. The modules went into an enclosure to make the driver more of an instrument and less of a one-off, with a nice multi-turn pot and vernier knob for precise filter adjustment. It’s really kind of cool to watch the output beam change colors at the twist of a knob, and cooler still to realize how it all works.

We’ve been seeing a lot of [Les]’ optics projects lately, from homemade TEA lasers to blasting the Bayer filter off a digital camera, each as impressive as the last! Continue reading “Acousto-Optic Filter Uses Sound To Bend Light” →