Author: Dan Maloney

3366 Articles

Taking A Public Transit Display From Project To Product

November 17, 2023 by 16 Comments

We’ve noticed an uptick in “project to product” stories lately, which seems like a fantastic trend to us. It means that hackers are turning out projects that really resonate with people, to the degree that taking the leap and scaling up from a one-off to a marketable product is worth the inherent risk. And luckily enough for the rest of us, we get to learn from their experiences.

The latest example of this comes to us from [Stefan Schüller], who from the sound of things only reluctantly undertook the conversion of his LED matrix public transit sign into an actual product. The original project had a lot going for it; it looked fantastic, it was technologically simple, and it provided a valuable service. But as a project, it made certain assumptions and concessions that would cause problems when in the hands of a customer. Chief among these was the physical protection of the fragile LEDs, which could easily shear off the display modules if bumped or dropped. There were also firmware issues, such as access to the backend API that serves the transit data; requiring each customer to sign up for and configure their own API key is a non-starter for a product.

In the article, [Stefan] enumerates a long list of problems that going from project to product raises, as well as how he addressed them. The API issue was solved by implementing his own service, which acts as a middleman between the official API and his customers. A nice plexiglass and sheet-metal frame serves to protect the display, too. Design changes were made as well, not only to provide better functionality but to make manufacturing easier. [Stefan] also relates a tale of woe with regard to getting the display’s app into the app stores, something that few of us have to deal with when we’re just fiddling around with something on the bench.

All in all, [Stefan] does a great job walking us through the trials and tribulations of bringing a product to market. There are similar lessons in this production run scale-up, too, but with an entirely different level of project complexity.

A Canned Ham Ham Antenna

November 16, 2023 by 29 Comments

If you’d have asked us for odds on whether you could successfully turn a canned ham into an amateur radio antenna, we’d have declined the offer. Now, having seen [Ben Eadie (VE6SFX)]’s “hamtenna” project, we’d look at just about any “Will it antenna?” project with a lot less skepticism than before.

To be painfully and somewhat unnecessarily clear about [Ben]’s antenna, the meat-like product itself is not in the BOM for this build, although he did use it as sustenance. Rather, it was the emptied and cleaned metal can that was the chief component of the build, along with a few 3D printed standoffs and the usual feedline and connectors. This is a slot antenna, a design [Ben] recently experimented with by applying copper foil tape to his car’s sunroof. This time around, the slot was formed by separating the top and bottom of the can using the standoffs and electrically connecting them with a strip of copper tape.

Connected to a stub of coax and a BNC connector, a quick scan with a NanoVNA showed a fantastic 1.26:1 SWR in the center of the 70-cm ham band, and a nearly flat response all the way across the band. Results may vary depending on the size of canned ham you sacrifice for this project; [Ben]’s can measured just about 35 cm around, a happy half-wavelength coincidence. And it actually worked in field tests — he was able to hit a local repeater and got good signal reports. All that and a sandwich? Not too shabby.

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Umbrella Antenna Protects You From Rain, But Not The Way You Think

November 16, 2023 by 8 Comments

You never know when you’ll be called upon to [MacGyver] your way out of an emergency. We can’t imagine what kind of situation would call for whipping up a satellite ground station for NOAA weather satellites from junk, but hey, it could happen.

And when it does, you’ll be ready — as long as you have an umbrella, some foil tape, and various bits and bobs like wire and an RTL-SDR dongle. That’s what [saveitforparts] used for his field-expedient build, at least in the first instance; as you can imagine, builds like this take a lot of tweaking to get right. The umbrella and foil tape form the main reflector for the antenna, with a pie tin, a scrap of wire, and some random twigs being used to build the antenna’s helical feed. Attached to a SAWbird LNA/filter and an RTL-SDR plugged into a dodgy second-hand phone, he was able to get at least some kind of data from one of the GOES satellites, but it wasn’t great.

Switching the feed to a commercially available log periodic antenna worked much better, with some partial decodes of weather map data. Actually, getting anything at all with a setup like this is impressive enough for us to call it a win. It shows that the umbrella approach to antennas is valid; but then again, we already knew that.

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A 3D Printed Grinder For Printed Lens Blanks

November 16, 2023 by 20 Comments

When one thinks of applications for 3D printing, optical components don’t seem to be a good fit. With the possible exception of Fresnel lenses, FDM printing doesn’t seem up to the job of getting the smooth surfaces and precision dimensions needed to focus light. Resin printing might be a little closer to the mark, but there’s still a long way to go between a printed blank and a finished lens.

That gap is what [Fraens] aims to fill with this homebrew lens grinding machine. It uses the same basic methods used to grind and polish lenses for centuries, only with printed components and lens blanks. The machine itself consists of a motorized chuck for holding the lens blank, plus an articulated arm to hold the polishing tool. The tool arm has an eccentric drive that wobbles the polishing tool back and forth across the blank while it rotates in the chuck. Lens grinding requires a lot of water and abrasive, so a large bowl is provided to catch the swarf and keep the work area clean.

Lens blanks are printed to approximately their finished dimensions using clear resin in an SLA printer. [Fraens] spent a lot of time optimizing the printing geometry to minimize the number of print layers required. He found that a 30° angle between the lens and the resin pool worked best, resulting in the clearest blanks. To polish the rough blanks, a lapping tool is made from polymer modeling clay; after baking it dry, the tool can hold a variety of pads and polishing compounds. From there it’s just a matter of running the blank through a range of abrasives to get the desired final surface.

Are the lenses fantastic? Well, they’re probably not going to make it into fine optical equipment, but they’re a lot better than you might expect. Of course, there’s plenty of room for improvement; better resins might result in clearer blanks, and perhaps degassing the uncured resin under vacuum might help with bubbles. Skipping the printed blanks and going with CNC-machined acrylic might be worth a try, too.

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Lessons In Mass Production From An Atari Punk Console

November 16, 2023 by 7 Comments

Sometimes the most interesting part of a project isn’t the widget itself, but what it teaches you about the manufacturing process. The story of the manufacturing scale-up of this Atari Punk Console and the lessons learned along the way is a perfect example of this.

Now, don’t get us wrong — we love Atari Punk Consoles. Anything with a couple of 555s that bleeps and bloops is OK in our books. But as [Adam Gulyas] tells the tale, the point of this project was less about the circuit than about the process of making a small batch of something. The APC was low-hanging fruit in that regard, and after a quick round of breadboarding to decide on component values, it was off to production. [Adam] was shooting for 20 units, each in a nice enclosure and a classy package. PCB assemblies were ordered, as were off-the-shelf plastic enclosures, which ended up needing a lot of tweaking. [Adam] designed custom labels for the cases, itself a fraught job; glossy label stock and button bezels apparently don’t mix.

After slogging through the assembly process, boxing the units for shipping was the next job. [Adam] sourced jewelry boxes just a bit bigger than the finished APCs, and rather than settle for tissue paper or packing peanuts, designed an insert to hold the units snugly. That involved a lot of trial and error and a little bit of origami-fu, and the results are pretty nice. His cost per unit came out to just a hair over $20 Canadian, including the packaging, which is actually pretty remarkable for such a short production run.

[Adam] includes a list of improvements for larger-scale runs, including ordering assembled PCBs, outsourcing the printing processes, and getting custom boxes made so no insert is needed. Any way you cut it, this production run came out great and teaches us all some important lessons.

Don’t Look Up, Or You’ll See The Time From This VFD Projection Clock

November 15, 2023 by 19 Comments

Ceiling clocks were a bit of a thing back in the days when clock radios were a fixture of nightstands. The idea was to project the time onto the ceiling so you’d only have to roll over onto your back and open your eyes to check the time, instead of potentially disturbing your slumber by craning your neck around to see the front of the clock.

As we recall, what sounded like a good idea was iffy in practice, with low-end optics and either weak incandescent bulbs or blazing LEDs. This nifty VFD projection clock by [Thomas Shupfs] seeks to fix those problems, and from the look of it does a pretty good job. It takes advantage of something else that fell out of favor with consumers — analog photography — by tapping into the ready supply of unwanted lenses. He paired that up with an IVL2-7/5 vacuum fluorescent display inside a 3D printed case with a cone-shaped extension to hold the lens at the right distance above the display. [Thomas] says that the STM32 software only supports JSON-RPC over USB at this time, and includes a couple of Python programs with examples of how to set the time and check the accuracy of the clock.

[Thomas] compares the clock head-to-head against his old LED projection clock, as seen in the featured image above; we flipped it for a better idea of what it would look like from bed. We’ve got to say the soft blue glow of the VFD would be a lot more pleasant to wake up to than the bright red LED projection. But this soft white projection clock is nice too.

Thanks to [skymab] for the tip.

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Hackaday Links: November 12, 2023

November 12, 2023 by 11 Comments

Somebody must really have it in for Cruise, because the bad press just keeps piling up for the robo-taxi company. We’ve highlighted many of the company’s woes in this space, from unscheduled rendezvous with various vehicles to random acts of vandalism and stupid AI pranks. The hits kept coming as California regulators pulled the plug on testing, which finally convinced parent company General Motors to put a halt to the whole Cruise testing program nationwide. You’d think that would be enough, but no — now we learn that Cruise cars had a problem recognizing children, to the point that there was concern that one of their autonomous cars could clobber a kid under the right conditions. The fact that they apparently knew this and kept sending cars out for IRL testing is a pretty bad look, to say the least. Sadly but predictably, Cruise has announced layoffs, starting with the employees who supported the now-mothballed robo-taxi fleet, including those who had the unenviable job of cleaning the cars after, err, being enjoyed by customers. It seems a bit wrongheaded to sack people who had no hand in engineering the cars, but then again, there seems to be a lot of wrongheadedness to go around.

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