Author: Dan Maloney

3369 Articles

DIY Spacer Increases FDM Flow Rate For Faster, Better Printing

July 12, 2024 by 8 Comments

The host of problems to deal with when you’re feeling the need for FDM speed are many and varied, but high on the list is figuring out how to melt filament fast enough to accommodate high flow rates. Plus, the filament must be melted completely; a melty outside and a crunchy inside might be good for snacks, but not for 3D printing. Luckily, budget-minded hobbyists can build a drop-in booster to increase volumetric flow using only basic tools and materials.

[aamott]’s booster, which started life as a copper screw, is designed to replace the standard spacer in an extruder, with a bore that narrows as the filament gets closer to the nozzle to ensure that the core of the filament melts completely. Rather than a lathe, [aamott]’s main tool is a drill press, which he used to drill a 0.7 mm bore through the screw using a PCB drill bit. The hole was reamed out with a 10° CNC engraving bit, generating the required taper. After cutting off the head of the screw and cleaning up the faces, he cut radial slots into the body of the booster by threading the blade of a jeweler’s saw into the bore. The result was a bore wide enough to accept the filament on one end, narrowing to a (roughly) cross-shaped profile at the other.

Stacked up with a couple of knock-off Bondtech CHT nozzles, the effect of the booster was impressive — a 50% increase in flow rate. It’s not bad for a prototype made with simple tools, and it looks a little easier to build than [Stefan]’s take on the same idea.

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Celebrating The [Jack Ells] Automatic Photometric Telescope

July 11, 2024 by 5 Comments

Here at Hackaday, we take pride in presenting the freshest hacks and the best of what’s going on today in the world of hardware hacking. But sometimes, we stumble upon a hack from the past so compelling that we’ve got to bring it to you, so we can all marvel at what was possible in the Before Times.

This one, a completely homebrewed automatic photometric telescope, was designed and built by the father-son team of [Jack Ells] and [Peter Ells]. From the elder [Ells]’ field notes, the telescope saw its first light in 1988, giving us some idea of the scale of problems that had to be overcome to get this wonderful machine working. The optics are straightforward, as least as telescopes go — it’s an f-4.0 Newtonian reflector with an 8.5″ (221 mm) primary mirror on an equatorial mount. The telescope is very rugged-looking indeed, and even stands on brick piers for stability. The telescope’s mount is controlled by a BBC Micro running custom BASIC software.

For the photometric parts, the [Ells] boys installed a photo-multiplier tube at the focus of the telescope. More precisely, they used a liquid light guide to connect the eyepiece to a rack full of equipment, which included the PM tube, its high-voltage power supply, and a series of signal conditioners and counter circuits. The idea was to view a single star through a pinhole mask over the objective of the telescope and count the rate of photons received over time. Doing so would reveal periodic changes in the star’s brightness. Today we’d use similar data to search for exoplanet transits; while we don’t think that was a thing back in 1988, it looks like this telescope could easily have handled the job.

Sadly, [Jack Ells] died only two years after finishing the telescope. But he left it with his son, who eventually moved it to a location with better seeing conditions, where it gathered data for another eight years. The quality of the work is amazing, and as father-son projects go, this one is tough to beat.

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Model Rocket Nails Vertical Landing After Three-Year Effort

July 10, 2024 by 30 Comments

Model rocketry has always taken cues from what’s happening in the world of full-scale rockets, with amateur rocketeers doing their best to incorporate the technologies and methods into their creations. That’s not always an easy proposition, though, as this three-year effort to nail a SpaceX-style vertical landing aptly shows.

First of all, hats off to high schooler [Aryan Kapoor] from JRD Propulsion for his tenacity with this project. He started in 2021 with none of the basic skills needed to pull off something like this, but it seems like he quickly learned the ropes. His development program was comprehensive, with static test vehicles, a low-altitude hopper, and extensive testing of the key technology: thrust-vector control. His rocket uses two solid-propellant motors stacked on top of each other, one for ascent and one for descent and landing. They both live in a 3D printed gimbal mount with two servos that give the stack plus and minus seven degrees of thrust vectoring in two dimensions, which is controlled by a custom flight computer with a barometric altimeter and an inertial measurement unit. The landing gear is also clever, using rubber bands to absorb landing forces and syringes as dampers.

The video below shows the first successful test flight and landing. Being a low-altitude flight, everything happens very quickly, which probably made programming a challenge. It looked like the landing engine wasn’t going to fire as the rocket came down significantly off-plumb, but when it finally did light up the rocket straightened and nailed the landing. [Aryan] explains the major bump after the first touchdown as caused by the ascent engine failing to eject; the landing gear and the flight controller handled the extra landing mass with aplomb.

All in all, very nice work from [Aryan], and we’re keen to see this one progress.

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Hackable Ham Radio Gives Up Its Mechanical Secrets

July 9, 2024 by 4 Comments

Reverse-engineered schematics are de rigeur around these parts, largely because they’re often the key to very cool hardware hacks. We don’t get to see many mechanical reverse-engineering efforts, though, which is a pity because electronic hacks often literally don’t stand on their own. That’s why these reverse-engineered mechanical diagrams of the Quansheng UV-K5 portable amateur radio transceiver really caught our eye.

Part of the reason for the dearth of mechanical diagrams for devices, even one as electrically and computationally hackable as the UV-K5, is that mechanical diagrams are a lot less abstract than a schematic or even firmware. Luckily, this fact didn’t daunt [mdlougheed] from putting a stripped-down UV-K5 under a camera for a series of images to gather the raw data needed by photogrammetry package RealityCapture. The point cloud was thoughtfully scaled to match the dimensions of the radio’s reverse-engineered PC board, so the two models can work together.

The results are pretty impressive, especially for a first effort, and should make electromechanical modifications to the radio all the easier to accomplish. Hats off to [mdlougheed] for the good work, and let the mechanical hacks begin.

Keep Your Lungs Clean And Happy With A DIY Supplied-Air Respirator

July 9, 2024 by 13 Comments

The smell of resin SLA printing is like the weather — everybody complains about it, but nobody does anything about it. At least until now, as [Aris Alder] tackles the problem with an affordable DIY supplied-air respirator.

Now, we know what you’re thinking, anything as critical as breathing is probably best left to the professionals. While we agree in principle, most solutions from reputable companies would cost multiple thousands of dollars to accomplish, making it hard to justify for a home gamer who just doesn’t want to breathe in nasty volatile organic compounds. [Aris] starts the video below with a careful examination of the different available respirator options, concluding that a supplied air respirator (SAR) is the way to go.

His homebrew version consists of an affordable, commercially available plastic hood with a built-in visor. Rather than an expensive oil-free compressor to supply the needed airflow, he sourced a low-cost inline duct fan and placed it outside the work zone to pull in fresh air. Connecting the two is low-cost polyethylene tubing and a couple of 3D printed adapters. This has the advantage of being very lightweight and less likely to yank the hood off your head, and can be replaced in a few seconds when it inevitably punctures.

Another vital part of the kit is a pulse oximeter, which [Aris] uses to make sure he’s getting enough oxygen. His O2 saturation actually goes up from his baseline when the hood is on and powered up, which bodes well for the system. Every time we pick up the welding torch or angle grinder we wish for something like this, so it might just be time to build one.

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Solar Dynamics Observatory: Our Solar Early Warning System

July 9, 2024 by 3 Comments

Ever since the beginning of the Space Age, the inner planets and the Earth-Moon system have received the lion’s share of attention. That makes sense; it’s a whole lot easier to get to the Moon, or even to Mars, than it is to get to Saturn or Neptune. And so our probes have mostly plied the relatively cozy confines inside the asteroid belt, visiting every world within them and sometimes landing on the surface and making a few holes or even leaving some footprints.

But there’s still one place within this warm and familiar neighborhood that remains mysterious and relatively unvisited: the Sun. That seems strange, since our star is the source of all energy for our world and the system in general, and its constant emissions across the electromagnetic spectrum and its occasional physical outbursts are literally a matter of life and death for us. When the Sun sneezes, we can get sick, and it has the potential to be far worse than just a cold.

While we’ve had a succession of satellites over the last decades that have specialized in watching the Sun, it’s not the easiest celestial body to observe. Most spacecraft go to great lengths to avoid the Sun’s abuse, and building anything to withstand the lashing our star can dish out is a tough task. But there’s one satellite that takes everything that the Sun dishes out and turns it into a near-constant stream of high-quality data, and it’s been doing it for almost 15 years now. The Solar Dynamics Observatory, or SDO, has also provided stunning images of the Sun, like this CGI-like sequence of a failed solar eruption. Images like that have captured imaginations during this surprisingly active solar cycle, and emphasized the importance of SDO in our solar early warning system.

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Going Ham Mobile On A Bicycle

July 8, 2024 by 19 Comments

It’s said that “Golf is a good walk spoiled,” so is attaching an amateur radio to a bike a formula for spoiling a nice ride?

Not according to [Wesley Pidhaychuk (VA5MUD)], a Canadian ham who tricked out his bike with a transceiver and all the accessories needed to work the HF bands while peddling along. The radio is a Yaesu FT-891, a workhorse mobile rig covering everything from the 160-meter band to 6 meters. [Wes] used some specialized brackets to mount the radio’s remote control head to the handlebars, along with an iPad for logging and a phone holder for streaming. The radio plus a LiFePO4 battery live in a bag on the parcel rack in back. The antenna is a Ham Stick mounted to a mirror bracket attached to the parcel rack; we’d have thought the relatively small bike frame would make a poor counterpoise for the antenna, but it seems to work fine — well enough for [Wes] to work some pretty long contacts while pedaling around Saskatoon, including hams in California and Iowa.

The prize contact, though, was with [WA7FLY], another mobile operator whose ride is even more unique: a 737 flying over Yuma, Arizona. We always knew commercial jets have HF rigs, but it never occurred to us that a pilot who’s also a ham might while away the autopilot hours working the bands from 30,000 feet. It makes sense, though; after all, if truckers do it, why not pilots?

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