Modeling Space Hack Chat

October 2, 2023 by Dan Maloney 1 Comment

Join us on Wednesday, October 4 at noon Pacific for the Modeling Space Hack Chat with Bryan Murphy and Sam Treadgold!

We’re going to go out on a limb here and guess that a fair number of Hackaday readers went through a phase of model building growing up. To further push out that branch, we’ll further guess that some of those models included spacecraft, both real and imaginary. And with good reason — you don’t get to space without some interesting engineering, a lot of which is reflected in the design of the vehicles intended to get there. Rockets are cool, satellites are cooler still, and if you can’t actually go to space yourself, or at least be the person building the actual hardware, at least you can build a model and dare to dream.

But while a model on a stand or hanging from the ceiling on fishing line can certainly stimulate the imagination, wouldn’t it be better if a model did something? Bryan Murphy and Sam Treadgold think so, which is why they’ve been working on the “ISS Mimic,” which we recently featured. The 3D-printed 1:100 scale model of the International Space Station is equipped with servos that move the station’s solar panels in real-time based on publically available telemetry. It’s way more engaging than a static model, especially for kids just getting into STEM and related fields.

Bryan and Sam will stop by the Hack Chat to talk not just about the ISS Mimic, but about everything that has to do with modeling space. Who wouldn’t love a desktop version of a Martian or lunar rover keeping pace with its full-scale counterpart? And wouldn’t it be great to be able to visualize just how far away Voyager is right now? If it’s out there, we should be able to bring it home, at least in model form.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, October 4 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

Hackaday Links: October 1, 2023

October 1, 2023 by Dan Maloney 13 Comments

We’ve devoted a fair amount of virtual ink here to casting shade at self-driving vehicles, especially lately with all the robo-taxi fiascos that seem to keep cropping up in cities serving as testbeds. It’s hard not to, especially when an entire fleet of taxis seems to spontaneously congregate at a single point, or all it takes to create gridlock is a couple of traffic cones. We know that these are essentially beta tests whose whole point is to find and fix points of failure before widespread deployment, and that any failure is likely to be very public and very costly. But there’s someone else in the self-driving vehicle business with way, WAY more to lose if something goes wrong but still seems to be nailing it every day. Of course, we’re talking about NASA and the Perseverance rover, which just completed a record drive across Jezero crater on autopilot. The 759-meter jaunt was completely planned by the onboard AutoNav system, which used the rover’s cameras and sensors to pick its way through a boulder-strewn field. Of course, the trip took six sols to complete, which probably would result in negative reviews for a robo-taxi on Earth, and then there’s the whole thing about NASA having a much bigger pot of money to draw from than any start-up could ever dream of. Still, it’d be nice to see some of the tech on Perseverance filtering down to Earth.

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Simple Add-On Makes Cheap Plasma Cutter Suitable For CNC Use

September 30, 2023 by Dan Maloney 15 Comments

Plasma cutters are ridiculously cheap these days, just cruise by the usual online sources or your local Harbor Freight if you’ve got any doubt about that. But “cheap” and “good” don’t always intersect on a Venn diagram, and even when they do, not every plasma cutter is suitable for use on the spanking new CNC table you’re building. But luckily, there’s a mod for that.

As [Jake von Slatt] explains it, there are two kinds of plasma cutters on the market: high-frequency (HF) start and pilot arc start. The basic difference is that HF start cutters, which comprise the majority of cheap cutters on the market, need direct electrical contact with the workpiece to start the cutting action. Pilot arc torches, which are more suitable for CNC cutters, can strike the arc through a separate conductor without the need to contact the workpiece.

While there are homebrew bodges that claim to turn an HF torch into a pilot arc, [Jake]’s approach is a bit more complicated, and necessarily so. His add-on box intercepts the ground clamp — which is actually the positive conductor for plasma cutting — and switches it through a heavy-duty HVAC contactor. The 24 VDC coil of the contactor is controlled by a homebrew current sensor made from a huge toroid ferrite core wrapped with 20 turns of 6 AWG welding wire.

Before winding, the core is split in two and epoxied back together with a small magnetic reed switch bridging the gap. A simple 24 VDC power supply runs the whole thing. When the torch starts, the nozzle is connected to ground through the contactor, but as soon as the arc strikes and starts pulling cutting current through that toroid, the magnetic field closes the reed switch, which opens the contactor via a small DC relay. This removes the connection between the nozzle and ground, leaving the plasma to carry all the cutting current.

We’ve featured many, many CNC plasma cutter tables before, but most of these builds have concentrated on the table more than the cutter. It’s a refreshing change to get some insider tips on what kinds of cutters work best, and how to adapt what you’ve got for the job.

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Looking Inside A 3D Printer Nozzle With Computed Tomography

September 28, 2023 by Dan Maloney 16 Comments

Have you ever wondered what’s actually going on inside the hotend of your 3D printer? It doesn’t seem like much of a mystery — the filament gets melty, it gets squeezed out by the pressure of the incoming unmelty filament, and lather, rinse, repeat. Or is there perhaps more to the story?

To find out, a team from the University of Stuttgart led by [Marc Kreutzbruck] took the unusual step of putting the business end of a 3D printer into a CT scanner, to get a detailed look at what’s actually going on in there. The test setup consisted of a Bondtech LGX extruder and an E3D V6 hot end mounted to a static frame. There was no need for X-Y-Z motion control during these experiments, but a load cell was added to measure extrusion force. The filament was a bit specialized — high-impact polystyrene (HIPS) mixed with a little bit of tungsten powder added (1% by volume) for better contrast to X-ray. The test system was small enough to be placed inside a micro CT scanner, which generated both 360-degree computed tomography images and 2D radiographs.

The observations made with this experimental setup were pretty eye-opening. The main take-home message is that higher filament speed translates to less contact area between the nozzle wall and the melt, thanks to an air gap between the solid filament and the metal of the nozzle. They also saw an increased tendency for the incoming filament to buckle at high extruder speeds, which matches up with practical experience. Also, filament speed is more determinative of print quality (as measured by extrusion force) than heater temperature is. Although both obviously play a role, they recommend that if higher print speed is needed, the best thing to optimize is hot end geometry, specifically an extended barrel to allow for sufficient melting time.

Earth-shattering stuff? Probably not, but it’s nice to see someone doing a systematic study on this, rather than relying on seat-of-the-pants observations. And the images are pretty cool too.

Testing Oxide Etchants For The Home Semiconductor Fab

September 27, 2023 by Dan Maloney 3 Comments

Building circuits on a silicon chip is a bit like a game of Tetris — you have to lay down layer after layer of different materials while lining up holes in the existing layers with blocks of the correct shape on new layers. Of course, Tetris generally doesn’t require you to use insanely high temperatures and spectacularly toxic chemicals to play. Or maybe it does; we haven’t played the game in a while, so they might have nerfed things.

Luckily, [ProjectsInFlight] doesn’t treat his efforts to build semiconductors at home like a game — in fact, the first half of his video on etching oxide layers on silicon chips is devoted to the dangers of hydrofluoric acid. As it turns out, despite the fact that HF can dissolve your skin, sear your lungs, and stop your heart, as long as you use a dilute solution of the stuff and take proper precautions, you should be pretty safe around it. This makes sense, since HF is present in small amounts in all manner of consumer products, many of which are methodically tested in search of a practical way to remove oxides from silicon, which [ProjectsInFlight] has spent so much effort recently to learn how to deposit. But such is the ironic lot of a chip maker.

Three products were tested — rust remover, glass etching cream, and a dental porcelain etching gel — against a 300 nm silicon dioxide layer. Etch speed varied widely, from rust remover’s 10 nm/min to glass etching cream’s blazing 240 nm/min — we wonder if that could be moderated by thinning the cream out with a bit of water. Each solution had pros and cons; the liquid rust remover was cheap easy to handle and clean up, while the dental etching gel was extremely easy to deposit but pretty expensive.

The good news was that everything worked, and each performed differently enough that [ProjectsInFlight] now has a range of tools to choose from. We’re looking forward to seeing what’s next — looks like it’ll be masking techniques.

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Keebin’ With Kristina Hack Chat

September 25, 2023 by Dan Maloney 3 Comments

Join us on Wednesday, September 27 at noon Pacific for the Keebin’ with Kristina Hack Chat with our own Kristina Panos!

When you think about it, wiggling your fingers over a bunch of magic chiclets is a pretty strange gateway to the written word. And yet, here we sit a hundred-odd years after someone first decided that the same basic interface used to run pianos and harpsichords for centuries would be a fantastic model for mechanizing the whole writing thing. Just because it makes perfect sense thanks to the outsized portion of our brains dedicated to the motor and sensory functions of our wonderfully complex and versatile hands doesn’t mean it’s not weird.

Still and all, it seems like there could be some room for improvement in the basic design of keyboards. We could probably do with something that makes typing easier, results in less repetitive strain, or is just more fun to do. Pushing back on the traditional and boring designs of the past is where we find the strange breed of keyboard builders and modders that our very own Kristina Panos counts herself part of. You know here from her popular “Keebin’ with Kristina” series, and now we’ve coaxed her into checking into the Hack Chat to talk to all the rest of us keyboard-minded individuals. If you’ve ever thought that there has to be a better way to enter text, or even just something a little bit different, you’ll want to come along and join the conversation.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, September 27 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

DIY Repair Brings An X-Ray Microscope Back Into Focus

September 22, 2023 by Dan Maloney 6 Comments

Aside from idle curiosity, very few of us need to see inside chips and components to diagnose a circuit. But reverse engineering is another story; being able to see what lies beneath the inscrutable epoxy blobs that protect the silicon within is a vital capability, one that might justify the expense involved in procuring an X-ray imager. But what’s to be done when such an exotic and expensive — not to mention potentially deadly — machine breaks down? Obviously, you fix it yourself!

To be fair, [Shahriar]’s Faxitron MX-20 digital X-ray microscope was only a little wonky. It still generally worked, but just took a while to snap into the kind of sharp focus that he needs to really delve into the guts of a chip. This one problem was more than enough to justify tearing into the machine, but not without first reviewing the essentials of X-ray production — a subject that we’ve given a detailed look, too — to better understand the potential hazards of a DIY repair.

With that out of the way and with the machine completely powered down, [Shahriar] got down to the repair. The engineering of the instrument is pretty impressive, as it should be for something dealing with high voltage, heavy thermal loads, and ionizing radiation. The power supply board was an obvious place to start, since electrostatically focusing an X-ray beam depends on controlling the high voltage on the cathode cup. After confirming the high-voltage module was still working, [Shahriar] homed in on a potential culprit — a DIP reed relay.

Replacing that did the trick, enough so that he was able to image the bad component with the X-ray imager. The images are amazing; you can clearly see the dual magnetic reed switches, and the focus is so sharp you can make out the wire of the coil. There are a couple of other X-ray treats, so make sure you check them out in the video below.

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