Author: Dan Maloney

3305 Articles

Fail Of The Week: Upcycling Failed 3D Prints

November 8, 2016 by 29 Comments

Is it possible to recycle failed 3D prints? As it turns out, it is — as long as your definition of “recycle” is somewhat flexible. After all, the world only needs so many coasters.

To be fair, [Devin]’s experiment is more about the upcycling side of the recycling equation, but it was certainly worth undertaking. 3D printing has hardly been reduced to practice, and anyone who spends any time printing knows that it’s easy to mess up. [Devin]’s process starts when the colorful contents of a bin full of failed prints are crushed with a hammer. Spread out onto a properly prepared (and never to be used again for cookies) baking sheet and cooked in the oven at low heat, the plastic chunks slowly melt into a thin, even sheet.

[Devin]’s goal was to cast them into a usable object, so he tried to make a bowl. He tried reheating discs of the material using an inverted metal bowl as a form but he found that the plastic didn’t soften evenly, resulting in Dali-esque bowls with thin spots and holes. He then flipped the bowl and tried to let the material sag into the form; that worked a little better but it still wasn’t the win he was looking for.

In the end, all [Devin] really ended up with is some objets d’art and a couple of leaky bowls. What else could he have done with the plastic? Would he have been better off vacuum forming the bowls or perhaps even pressure forming them? Or does the upcycling make no sense when you can theoretically make your own filament? Let us know in the comments how you would improve this process.

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Neopixels Light The Way In Pressure-Sensitive Floor

November 7, 2016 by 8 Comments

It’s got a little “Saturday Night Fever” vibe to it, but this pressure-sensitive LED floor was made for gaming, not for dancing.

Either way, [creed_bratton_]’s build looks pretty good. The floor is a 5×6 grid of thick HDPE cutting boards raised up on a 2×4 lumber frame. Each cell has a Neopixel ring and a single force-sensitive resistor to detect pressure on the pad. Two 16-channel multiplexers were needed to consolidate the inputs for the Arduino that’s running the show, and a whole bunch of wall warts power everything. The video below shows a little of the build and a look under the tiles. It’s not clear exactly what game this floor is for, but you can easily imagine a maze or some other puzzle that needs to be solved with footsteps.

Light-up floors are nothing new here, what with this swimming pool dance floor. But this interactive dance floor comes close to the gaming aspect of [creed_bratton_]’s build.

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IoT Coop Door Cares For Chickens, Tests Home Automation

November 6, 2016 by 28 Comments

Most chickens are pretty good at putting themselves to bed when the sun sets, and [Eddy]’s chickens are no exception. But they’re not terribly thoughtful about closing up after themselves, so he set about on a long-term project to automate the door of their coop.

An open door overnight leaves chickens and their food vulnerable to predation. Rather than handle the chore manually and risk one forgetful moment that could wipe out his flock, [Eddy] used a servo to power the door and an Arduino to control it. To keep track of bedtime and wakeup, a Raspberry Pi looks up the local civil dawn and twilight times online and tells the Arduino when the moment is at hand. The Pi cleverly caches the times for use the next day in case the WiFi connection is down, and also provides a web interface to check on the door’s status and manually override the cycle. Result: safe, happy chickens.

If all this seems a bit much for a simple job, [Eddy] agrees. But he’s using this as a testbed to develop a home automation framework that can be retasked at will. Sounds like he’s on the right track to us, but for more IoT animal husbandry tips, he’ll want to check out this small farm automation effort.

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3D Printer Tragedy Claims A Life

November 3, 2016 by 136 Comments

Thankfully it’s rare that we report on something as tragic as the death of a 17-year old, but the fact that the proximate cause was a 3D printer makes it all the worse and important for us to discuss.

The BBC report tells of a recently concluded coroner’s inquest into the December death of a young man in a fire at his family’s magic shop in Lincolnshire. The building was gutted by the fire, and the victim died of smoke inhalation. The inquest found that he had been working with a 3D printer in the shop and using hairspray to prepare the bed, a tip he apparently picked up from forums and blogs.

Unfortunately for this young man and his family, the online material didn’t mention that hairspray propellant contains volatile hydrocarbons like propane, cyclopropane, n-butane and isobutane — all highly flammable. Apparently the victim used enough hairspray in a small enough space to create an explosive mixture of fuel and air. Neighbors reported a gigantic fireball that consumed the shop, which took 50 firefighters to control.

While the inquest doesn’t directly blame the 3D printer as the source of ignition — which could just as easily have been a spark from a light switch, or a pilot light on a water heater — it does mention that the hot end can reach 300C. And the fact remains that were it not for the 3D printer and the online tips, it’s unlikely that a 17-year old boy would be using enough hairspray in an enclosed space to create what amounted to a bomb.

By all accounts, the victim was a bright and thoughtful kid, and for this to have happened is an unmitigated tragedy for his family and friends. This young man probably had a bright future and stood to contribute to the hacker community but for a brief lapse of judgment. Before anyone starts slinging around the blame in the comments section, think about it — how many time haves you done something like this and gotten away with it? This kid got badly unlucky and paid the ultimate price. Maybe we should make his death worth something by looking at what we do that skates a little too close to the thin edge of the ice.

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Rotary Cell Phone: Blast From A Past That Never Was

November 2, 2016 by 32 Comments

The 1970s called and they want their rotary dial cell phone back.

Looking for all the world like something assembled from the Radio Shack parts department – remember when Radio Shack sold parts? – [Mr_Volt]’s build is a celebration of the look and feel of a hobbyist build from way back when. Looking a little like a homebrew DynaTAC 8000X, the brushed aluminum and 3D-printed ABS case sports an unusual front panel feature – a working rotary dial. Smaller than even the Trimline phone’s rotating finger stop dial and best operated with a stylus, the dial translates rotary action to DTMF tones for the Feather FONA board inside. Far from a one-trick pony, the phone sports memory dialing, SMS messaging, and even an FM receiver. But most impressive and mysterious is the dial mechanism, visible through a window in the wood-grain back. Did [Mr_Volt] fabricate those gears and the governor? We’d love to hear the backstory on that.

This isn’t the first rotary cell phone hybrid we’ve featured, of course. There was this GSM addition to an old rotary phone and this cell phone that lets you slam the receiver down. But for our money a rotary dial cell phone built from the ground up wins the retro cool prize of the bunch.

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Hams In Space Part 2: The Manned Spaceflights

November 1, 2016 by 39 Comments

Whether it’s trying to make contacts across the planet with a transmitter that would have a hard time lighting an LED, or blasting signals into space and bouncing them off the moon, amateur radio operators have always been on the forefront of communications technology. As mankind took to space in the 1950s and 1960s, hams went along for the ride with the first private satellites. But as successful as the OSCAR satellites were, they were still at best only beacons or repeaters in space. What was needed was the human touch – a real live operator making contacts with people on the ground, showing the capabilities of amateur radio while generating public interest in the space program. What was needed was a ham in space. Continue reading “Hams In Space Part 2: The Manned Spaceflights” →

Primer On Servos Hits All The Basics

October 30, 2016 by 10 Comments

Servos are pretty basic fare for the seasoned hacker. But everyone has to start somewhere, and there’s sure to be someone who’ll benefit from this primer on servo internals. Who knows – maybe even the old hands will pick up something from a fresh perspective.

[GreatScott!] has been building a comprehensive library of basic electronics videos over the last few years that covers everything from using a multimeter to programming an Arduino. The last two installments delve into the electromechanical realm with a treatment of stepper motors along with the servo video below. He covers the essentials of the modern RC-type servo in a clear and engaging style that makes it easy for the newbie to understand how a PWM signal can translate into positional changes over a 180° sweep. He shows how to control a servo directly with an Arduino, with bonus points for including a simple 555-based controller circuit too. A quick look at the mods needed to convert any servo to continuous rotation wraps up the video.

If [GreatScott!]’s video whets your appetite for more, be sure to check out [Richard Baguley]’s deeper dive into servos. And when you’re ready to put your new-found knowledge into practice, maybe a nice project would be to convert a hobby servo into a linear actuator.

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