First Benchies In Stainless Steel, With Lasers

October 7, 2024 by Elliot Williams 19 Comments

DIY 3D printing in metal is a lot more complicated than we thought. And this video from [Metal Matters] shows two approaches, many many false starts, and finally, a glorious 78.9% success! (And it’s embedded below for your enjoyment.)

The first half of the video is dedicated to the work on a laser welding system that doesn’t pan out in the end at all. But the missteps are worth watching as well, and they hammer home the difficulties of melting metal reliably with nothing more than coherent light. Things like reflection, the difficulty of getting good process control cameras, and finally the whole thing slumping as multiple layers stack up on each other make this approach to 3D construction look nearly impossible.

Indeed, around halfway through the video, the focus shifts toward a metal-powder sintering machine, and this one is a success! Metal dust is deposited layer by layer, and fused with a totally different laser. The tricky bits here range from esoteric problems like making the laser fuse the metal dust without blasting it, to simple things like the geometry of the scraper that ensures even layer heights. And once you’ve got all that down, getting a good pattern down for 2D infill in metal is non-trivial.

A sweet half-scale metal Benchy emerges at the end, so why does [Metal Matters] call this a 78.9% success? Because that’s the density of the final print, and he is shooting for 100%. But we wouldn’t be so harsh. We’ve seen how far he’s come since the first machines, and this is a huge advance. We’re looking forward to the next video update in a year or two!

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Towards Solderless PCB Prototyping

October 6, 2024 by Elliot Williams 17 Comments

When we think of assembling a PCB, we’re almost always thinking about solder. Whether in paste form or on the spool, hand-iron or reflow, some molten metal is usually in the cards. [Stephen Hawes] is looking for a solderless alternative for prototyping, and he shows us the progress he’s made toward going solderless in this video.

His ulterior motive? He’s the designer of the LumenPNP open-source pick-and-place machine, and is toying with the idea of a full assembly based just on this one machine. If you strapped a conductive-glue extruder head on the machine in addition to the parts placer, you’d have a full assembly in one step. But we’re getting ahead of ourselves.

[Stephen] first tries Z-tape, which is really cool stuff. Small deformable metal balls are embedded in a gel-like tape, and conduct in only the Z direction when parts are pushed down hard into the tape. But Z-tape is very expensive, requires a bit of force to work reliably, and [Stephen] finds that the circuits are intermittent. In short, Z-tape is not a good fit for the PNP machine.

But what [Stephen] does find works well is a graphite-based conductive glue. In particular, he likes the Bare Conductive paint. He tries another carbon-based paint, but it’s so runny that application is difficult, while the Bare stuff is thick and sticky. (They won’t tell you their secret formula, but it’s no secret how the stuff is basically made.) That ends up looking very promising, but it’s still pretty spendy, and [Stephen] is looking to make his own conductive paste/paint pretty soon. That’s particularly appealing, because he can control the stickiness and viscosity, and he’ll surely let us in on the secret sauce.

(We’re armchair quarterbacking here, but the addition of a small amount of methyl cellulose and xanthan gum works to turn metal powder into a formable, printable metal clay, so it might make a carbon paste similarly adjustably sticky.)

We love the end-goal here: one machine that can apply a conductive paint and then put the parts into the right place, resulting in a rough-and-ready, but completely hands-off assembly. You probably wouldn’t want to use this technique if the joint resistance was critical, or if you needed the PCB to stand up to abuse. There’s a reason that everyone in industry uses molten metal, after all. But for verifying a quick one-off, or in a rapid-prototyping environment? This would be a dream.

We’ve seen other wacky ways to go solderless before. This one uses laser-cut parts to hold the components on the PCB, for instance. And for simply joining a couple wires together, we have many more solutions, many thanks to you all in the comments!

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Where Is The End Of DIY?

October 5, 2024 by Elliot Williams 72 Comments

Al and I were talking on the podcast about Dan Maloney’s recent piece on how lead and silver are refined and about the possibility of anyone fully understanding a modern cellphone. This lead to Al wondering at the complexity of the constructed world in which we live: If you think hard enough about anything around you right now, you’d probably be able to recreate about 0% of it again from first principles.

Smelting lead and building a cellphone are two sides of coin, in my mind. The process of getting lead out of galena is simple enough to comprehend, but it’s messy and dangerous in practice. Cellphones, on the other hand, are so monumentally complex that I’d wager that no single person could even describe all of the parts in sufficient detail to reproduce them. That’s why they’re made by companies with hundreds of engineers and decades of experience with the tech – the only way to build a cellphone is to split the complicated task into many subsystems.

Smelting lead is a bad DIY project because it’s simple in principle, but prohibitive in practice. Building a cellphone from the ground up is incomprehensible in principle, but ironically entirely doable in practice if you’re willing to buy into some abstractions.

Indeed, last week we saw a nearly completely open-source build of a simple smartphone, and the secret to making it work is knowing the limits of DIY. The cell modem, for instance, is a black box. It’s an abstract device that you can feed data to and read data from, and it handles the radio parts of the phone that would take forever to design from scratch. But you don’t need to understand its inner workings to use it. Knowing where the limits of DIY are in your project, where you’re willing to accept the abstraction and move on, can be critical to getting it done.

Of course, in an ideal world, you’d want the cell modem to be like smelting lead – something that’s possible to understand in principle but just not worth DIYing in practice. And of course, there are some folks out there who hack on cell modem firmware and others who could do the radio engineering. But despite my strong DIY urges, I’d have to admit that the essential complexity of the module simply makes it worth treating as a black box. It’s very probably the practical limit of DIY.

What’s The Deal With AI Art?

September 28, 2024 by Elliot Williams 103 Comments

A couple weeks ago, we had a kerfuffle here on Hackaday: A writer put out a piece with AI-generated headline art. It was, honestly, pretty good, but it was also subject to all of the usual horrors that get generated along the way. If you have played around with any of the image generators you know the AI-art uncanny style, where it looks good enough at first glance, but then you notice limbs in the wrong place if you look hard enough. We replaced it shortly after an editor noticed.

The story is that the writer couldn’t find any nice visuals to go with the blog post, with was about encoding data in QR codes and printing them out for storage. This is a problem we have frequently here, actually. When people write up a code hack, for instance, there’s usually just no good image to go along with it. Our writers have to get creative. In this case, he tossed it off to Stable Diffusion.

Some commenters were afraid that this meant that we were outsourcing work from our fantastic, and very human, art director Joe Kim, whose trademark style you’ve seen on many of our longer-form original articles. Of course we’re not! He’s a genius, and when we tell him we need some art about topics ranging from refining cobalt to Wimshurst machines to generate static electricity, he comes through. I think that all of us probably have wanted to make a poster out of one or more of his headline art pieces. Joe is a treasure.

But for our daily blog posts, which cover your works, we usually just use a picture of the project. We can’t ask Joe to make ten pieces of art per day, and we never have. At least as far as Hackaday is concerned, AI-generated art is just as good as finding some cleared-for-use clip art out there, right?

Except it’s not. There is a lot of uncertainty about the data that the algorithms are trained on, whether the copyright of the original artists was respected or needed to be, ethically or legally. Some people even worry that the whole thing is going to bring about the end of Art. (They worried about this at the introduction of the camera as well.) But then there’s also the extra limbs, and AI-generated art’s cliche styles, which we fear will get old and boring after we’re all saturated with them.

So we’re not using AI-generated art as a policy for now, but that’s not to say that we don’t see both the benefits and the risks. We’re not Luddites, after all, but we are also in favor of artists getting paid for their work, and of respect for the commons when people copyleft license their images. We’re very interested to see how this all plays out in the future, but for now, we’re sitting on the sidelines. Sorry if that means more headlines with colorful code!

2024 Hackaday Superconference Speakers, Round Two

September 25, 2024 by Elliot Williams 1 Comment

It’s honestly amazing the range of fascinating talks we have lined up for this year’s Supercon. From art robots that burp and belch to gliders returning from near-space, from hardcore DSP to DIY PCBs, and sketching with machines, Hackaday’s Supercon is like nothing else out there.

And in case you’re already coming, you don’t have a talk slot reserved, but you’ve still got something that you want to say, please sign yourself up for a Lightning Talk! In the spirit of the Lightning, we’ll be taking submissions up to the absolute last minute, and we will fit in as many short talks as possible, but when it does fill up, we’ll be giving priority to those who got in first.

We’ve got one more speaker announce coming up, and of course our keynote speaker and the badge reveal. Supercon will sell out so get your tickets now before it’s too late. So without further ado, here is our next round of stellar speakers!

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2024 Hackaday Supercon Workshop Tickets Go On Sale Now

September 24, 2024 by Elliot Williams 8 Comments

Our workshop ticket sales go live today at 8 AM PDT! If you’re coming to Supercon, and you’re interested, go get your workshop ticket before they all sell out!

There will be a change to this year’s workshop ticket limits. We heard our community’s feedback, and in the spirit of giving as many people as possible the opportunity to enjoy a workshop, we are limiting sign up to one workshop per attendee. If there are extra tickets by October 18th, we will allow folks to sign up for additional workshops.

If you register for more than one workshop we will refund you the ticket for the others based on the timestamp that you registered for each ticket (leaving only the ticket for the first workshop you registered for). We hope everyone understands our goal is to allow more people to experience a Supercon workshop due to limited space.

And of course, you can’t join in the workshops at Supercon without coming to Supercon. So get your tickets now if you haven’t already.

Stay tuned tomorrow for more speaker announcements!

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FreeCAD Is Near 1.0

September 21, 2024 by Elliot Williams 48 Comments

The open-source parametric 3D modelling software, FreeCAD, is out in a release candidate for version 1.0. If you’ve tried FreeCAD before and found a few showstoppers, it might be a good time for you to test it out again because the two biggest of them have been solved in this latest version.

First, version 1.0 finally implements a solution to the “topological naming problem”. Imagine you want to put a hole into a surface. The program needs to know on which surface to put the hole, and so it refers to this surface by name / number. Now imagine you subdivide the surface, and both subsections get new names. Where does your hole go now? If you want to dig into the issue, the inimitable [MangoJelly] has a great video about the topo naming problem. Practically, there were workarounds, like only adding chamfers after the main design has stabilized, but frankly it was a hassle to remember all of the tricks. This is a huge fix.

The second big fix concerns assemblies. Older versions of FreeCAD were great for making single parts, but combining them all together inside the CAD program was always janky. Version 1.0 combines the previous two patchwork assembly workbenches into one, and it’s altogether more pleasant to use. The constraints of how two parts move when held together with an axle just works now, and this is a big deal for multi-part models.

If you’re coming from any other parametric CAD program, most of FreeCAD will seem familiar to you, but there will also be workflow differences that will take some getting used to. In trade, what do you get? Scriptability in Python, real open source software, and all of the bells and whistles for free. Now that its two biggest pain points have been addressed, FreeCAD has become a lot easier to love. We’re looking forward to some good V1.0 tutorials in the future, and we’ll keep you posted when we find them.