Thermoforming Printed Parts With Hot Water

February 19, 2026 by Maya Posch 14 Comments

Thermoforming is the process of softening a material enough so that it can be tweaked into a new shape, with the source of the thermal energy being not particularly relevant. Correspondingly, after [Zion Brock]’s recent video on his journey into thermoforming PLA with a mold and a heat gun, he got many comments suggesting that he should use hot water instead.

We covered his previous video as well, in which he goes through the design steps of making these grilles for a retro-styled, 3D printed radio. The thermoforming method enables him to shape the curvy grille with a heat gun and two-piece mold in a matter of minutes, rather than spending hours more time printing and removing many supports.

Theoretically using hot water instead of hot air would provide a more equal application of heat, but putting your hands into 70°C water does require some more precautions. There’s also the issue that PLA is very hygroscopic, so the part requires drying afterwards to prevent accelerated hydrolysis. Due to the more even heating, the edge of the PLA that clamped into the mold also softened significantly, causing it to pop out of the mold and requiring a small design modification to prevent this.

Basically, aqua-thermoforming like this has many advantages, as its slower and more consistent, but it’s less straightforward to use than hot air. This makes both a useful tool when you’re looking at doing thermoforming.

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Creating The World’s Most Efficient Quadcopter Drone

February 18, 2026 by Maya Posch 12 Comments

Keeping an eye on remaining battery charge. (credit: Luke Maximo Bell, YouTube)

Although not a typical focus of people who fly quadcopter drones for a hobby or living, endurance flying has a certain appeal to it for the challenge it offers. Thus, as part of his efforts to collect all the world records pertaining to quadcopter drones, [Luke Maximo Bell] has been working on a design that would allow him to beat the record set by SiFly Aviation at 3 hours and 11 minutes.

By using knowledge gained from his PV solar-powered quadcopter, [Luke] set about to take it all a few steps further. The goal was to get as much performance out of a single Watt, which requires careful balancing of weight, power output and many other parameters.

Crucial is that power usage goes up drastically when you increase the RPM of the propellers, ergo massive 40″ propellers were picked to minimize the required RPM to achieve sufficient lift, necessitating a very large, but lightweight frame.

The battery packs are another major factor since they make up so much of the weight. By picking high-density Tattu batteries and stripping these down even more this was optimized for as well, before even the wire gauge of the power wires running to the motors were investigated to not waste a single Watt or gram.

All of this seems to have paid off, as a first serious test flight resulted in a 3 hour, 31 minutes result, making it quite feasible that [Luke] will succeed with his upcoming attempt at the world’s longest flying electric multirotor record. Another ace up his sleeve here is that of forward movement as well as wind provides effectively free lift, massively reducing power usage and possibly putting the 4 hour endurance score within easy reach.

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The Dismal Repairability Of Milwaukee Tools

February 18, 2026 by Maya Posch 64 Comments

Despite the best efforts of the manufacturers, there are folks out there that try to repair power tools, with [Dean Doherty] being one of them. Recently he got a Milwaukee M18 cordless planer in for repairs, which started off with just replacing some dodgy bearings, but ended up with diagnosing a faulty controller. Consequently the total repair costs went up from reasonable to absolutely unreasonable, leading to a rant on why Milwaukee tools are terrible to repair.

Among the symptoms was the deep-discharged battery, which had just a hair over 7 V while unloaded. Question was what had drained the battery so severely. What was clear was that the tool was completely seized after inserting a working battery with just a sad high-pitched whine from a stalled motor.

After replacing both bearings and grumbling about cheap bearings, the tool had a lot of drywall dust cleaned out and was reassembled for a test run. This sadly showed that the controller board had been destroyed due to the seized rotor bearing, explaining the drained battery. Replacing the controller would have cost €60-70 as it comes with the entire handle assembly, rendering the repair non-viable and a waste.

Perhaps the one lesson from this story is that you may as well preventively swap the cheap bearings in your Milwaukee tools, to prevent seizing and taking out the controller board. That said, we’d love to see an autopsy on this controller board fault.

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Using 3D Printed Breadboards To Accommodate Wide Boards

February 17, 2026 by Maya Posch 36 Comments

Although off-the-shelf breadboards are plentiful and cheap, they almost always seem to use the same basic design. Although you can clumsily reassemble most of them by removing the voltage rail section and merging a few boards together, wouldn’t it be nice if you had a breadboard that you could stick e.g. one of those wide ESP32 development boards onto and still have plenty of holes to poke wires and component leads into? Cue [Ludwin]’s 3D printable breadboard design that adds a big hole where otherwise wasted contact holes would be.

The related Instructables article provides a visual overview of the rationale and the assembly process. Obviously only the plastic shell of the breadboard is printed, after which the standard metal contacts are inserted. These contacts can be ‘borrowed’ from commercial boards, or you can buy the contacts separately.

For the design files there is a GitHub repository, with breadboard designs that target the ESP32, Raspberry Pi Pico, and the Arduino Nano. An overview of the currently available board designs is found on the Hackaday.io project page, with the top image showing many of them. In addition to the single big space design there are also a few variations that seek to accommodate just about any component and usage, making it rather versatile.

Performing An Autopsy On 15 Dead Battle Born LFP Batteries

February 16, 2026 by Maya Posch 21 Comments

More molten plastic spacers between the bus bar and terminal. (Credit: Will Prowse)

Because size matters when it comes to statistics, [Will Prowse] decided to not just bank on his handful of failed Battle Born LFP batteries when it came to documenting their failure modes. Instead he got a whole gaggle of them from a viewer who had experienced failures with their Battle Born LFP batteries for an autopsy, adding a total of 15 samples to the data set.

Interestingly, the symptoms of these dead batteries are all over the place, from a refusal to charge, some have the overheating terminal, some do not show any sign of life, others have charged cells but a non-responsive BMS, etc. As [Will] notes, it’s important to test batteries with a load and a charger to determine whether they are functional not just whether you can measure a charge.

Although some of the batteries still showed enough signs of life to be put aside for some load testing, the remaining ones were cut open to check their insides. This revealed the typical molten plastic at the terminals, but also a lot of very loose connections for the internal wiring. Another battery showed signs of corrosion inside, which could be due to either moisture intrusion or a cell having leaked its electrolyte.

While the full results will hopefully be released soon, the worrying thing about this latest batch of Battle Born LFP batteries is that they span quite a few years, with one being from 2018. Although it’s comforting that not every one of these batteries is necessarily going to catch on fire within its approximate 8-year lifespan, a lot seems to depend on exactly how you load and charge them, as [Will] is trying to figure out with the upcoming load testing. With the unit that he recently purchased for testing it turned out that lower currents actually made the melting problem much worse.

Between this video and the much awaited follow-up, [Will] actually got his hands on a troubled 300A-rated industrial Battle Born battery. During testing that one actually failed violently with a cell venting and the loose BMS rattling around in the case.

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What The FDA’s 2026 Wellness Device Update Means For Wearables

February 16, 2026 by Maya Posch 11 Comments

With more and more sensors being crammed into the consumer devices that many of us wear every day, the question of where medical devices begin and end, and how they should be regulated become ever more pertinent. When a ‘watch’ no longer just shows the time, but can keep track of a dozen vital measurements, and the line between ‘earbud’ and ‘hearing aid’ is a rather fuzzy one, this necessitates that institutions like the US FDA update their medical device rules, as was done recently in its 2026 update.

This determines how exactly these devices are regulated, and in how far their data can be used for medical purposes. An important clarification made in the 2026 update is the distinction between ‘medical information’ and ‘signals/patterns’. Meaning that while a non-calibrated fitness tracker or smart watch does not provide medically valid information, it can be used to detect patterns and events that warrant a closer look, such as indications of arrhythmia or low blood oxygen saturation.

As detailed in the IEEE Spectrum article, these consumer devices are thus ‘general wellness’ devices, and should be marketed as such, without embellished claims. Least of all should they be sold as devices that can provide medical information.

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How Volunteers Saved A Victorian-Era Pumping Station From Demolition

February 16, 2026 by Maya Posch 13 Comments

D-engine of the Claymills Pumping Station. (Credit: John M)

Although infrastructure like a 19th-century pumping station generally tends to be quietly decommissioned and demolished, sometimes you get enough people looking at such an object and wondering whether maybe it’d be worth preserving. Such was the case with the Claymills Pumping Station in Staffordshire, England. After starting operations in the late 19th century, the pumping station was in active use until 1971. In a recent documentary by the Claymills Pumping Station Trust, as the start of their YouTube channel, the derelict state of the station at the time is covered, as well as its long and arduous recovery since they acquired the site in 1993.

After its decommissioning, the station was eventually scheduled for demolition. Many parts had by that time been removed for display elsewhere, discarded, or outright stolen for the copper and brass. Of the four Woolf compounding rotative beam engines, units A and B had been shut down first and used for spare parts to keep the remaining units going. Along with groundwater intrusion and a decaying roof, it was in a sorry state after decades of neglect. Restoring it was a monumental task.

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