Build A 3D Printer Workhorse, Not An Amazing Disappointment Machine

July 6, 2016 by Moritz Walter 68 Comments

3D printers have become incredibly cheap, you can get a fully workable unit for $200 – even without throwing your money down a crowdfunded abyss. Looking at the folks who still buy kits or even build their own 3D printer from scratch, investing far more than those $200 and so many hours of work into a machine you can buy for cheap, the question “Why the heck would you do that?” may justifiably arise.

The answer is simple: DIY 3D printers done right are rugged workhorses. They work every single time, they never break, and even if: they are an inexhaustible source of spare parts for themselves. They have exactly the quality and functionality you build them to have. No clutter and nothing’s missing. However, the term DIY 3D printer, in its current commonly accepted use, actually means: the first and the last 3D printer someone ever built, which often ends in the amazing disappointment machine.

This post is dedicated to unlocking the full potential in all of these builds, and to turning almost any combination of threaded rods and plywood into a workshop-grade piece of equipment.

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Hackaday Prize Entry: Cheap, Open LiDAR

July 5, 2016 by Moritz Walter 19 Comments

[adam] is a caver, meaning that he likes to explore caves and map their inner structure. This is still commonly done using traditional tools, such as notebooks (the paper ones), tape measure, compasses, and inclinometers. [adam] wanted to upgrade his equipment, but found that industrial LiDAR 3D scanners are quite expensive. His Hackaday Prize entry, the Open LIDAR, is an affordable alternative to the expensive industrial 3D scanning solutions out there.

The 3D scan of a small cave near Louisville (source: [caver.adam's] Sketchfab repository) — The 3D scan of a small cave near Louisville from [caver.adam’s] Sketchfab repository

LiDAR — Light Detection And Ranging — is the technology that senses the distance between a sensor and an object by reflectively measuring the time of flight of a light beam between the two. By acquiring a two-dimensional array of multiple distance readings, this can be used for 3D scanning. Looking at how the industrial LiDAR scanners capture the environment using fast spinning mirrors, [adam] realized that he could basically achieve the same by using a cheap laser range finder strapped to a pan and tilt gimbal.

The gimbal he designed for this task uses stepper motors to aim an SF30-B laser rangefinder. An Arduino controls the movement and lets the eye of the sensor scan an object or an entire environment. By sampling the distance readings returned by the sensor, a point cloud is created which then can be converted into a 3D model. [adam] plans to drive the stepper motors in microstepping mode to increase the resolution of his scanner. We’re looking forwards to see the first renderings of 3D cave maps captured with the Open LIDAR.

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Hackaday Prize Entry: ESP Swiss Knife

July 4, 2016 by Moritz Walter 5 Comments

The best equipment won’t help you if you don’t have it with you in the moment you need it. Knowledge, experience, and a thick skin may help you out there in the mud of the hardware battlegrounds, but they can’t replace a multimeter, an oscilloscope, a logic analyzer, a serial console or a WiFi access point. [Arcadia Labs] has taken on the challenge of combining most of these functions into a single device, developing the Hacker’s equivalent of a Swiss Army Knife: The ESP Swiss Knife.

Just like a Swiss Army Knife is first and foremost a knife, the EPS Swiss Knife is first and foremost an ESP8266. That means it is already a great platform for any kind of project, and [Arcadia Labs] supercharged the plain ESP-12E module by adding a couple of useful features commonly used in many projects. There’s an OLED display, four pushbuttons, a temperature sensor, and a Li-Ion cell with a charging module to power the device on the go. A universal “utility socket” breaks out the ESP8266’s leftover GPIOs and the supply voltage for attaching further peripherals.

With the hardware up and running, [Arcadia Labs] went on with building a couple of applications to provide the functionality that would make the device earn its name. Among them is a basic oscilloscope, a digital NTP based clock, a thermometer, a WiFi tester, a weather station and a 3D printer status monitor. More applications are planned, such as a chronometer, a timer, a DSLR intervalometer and more. A protective 3D printable enclosure is also in the works. [Arcadia Labs] has been joining the Hackaday Prize 2014 and 2015 before and we’re glad to see another great build coming into existence!

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Hackaday Prize Entry: Dtto Modular Robot

July 3, 2016 by Moritz Walter 16 Comments

A robot to explore the unknown and automate tomorrow’s tasks and the ones after them needs to be extremely versatile. Ideally, it was capable of being any size, any shape, and any functionality, shapeless like water, flexible and smart. For his Hackaday Prize entry, [Alberto] is building such a modular, self-reconfiguring robot: Dtto.

To achieve the highest possible reconfigurability, [Alberto’s] robot is designed to be the building block of a larger, mechanical organism. Inspired by the similar MTRAN III, individual robots feature two actuated hinges that give them flexibility and the ability to move on their own. A coupling mechanism on both ends of the robot allows the little crawlers to self-assemble in various configurations and carry out complex tasks together. They can chain together to form a snake, turn into a wheel and even become four (or more) legged walkers. With six coupling faces on each robot, that allow for connections in four orientations, virtually any topology is possible.

Each robot contains two strong servos for the hinges and three smaller ones for the coupling mechanism. Alignment magnets help the robots to index against each other before a latch locks them in place. The clever mechanism doubles as an ejector, so connections can be undone against the force of the alignment magnets. Most of the electronics, including an Arduino Nano, a Bluetooth and a NRF24L01+ module, are densely mounted inside one end of the robot, while the other end can be used to add additional features, such as a camera module, an accelerometer and more. The following video shows four Dtto robots in a snake configuration crawling through a tube.

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Brasilia Espresso Machine PID Upgrade Brews Prefect Cup Of Energy

July 3, 2016 by Moritz Walter 20 Comments

Coffee, making and hacking addictions are just bound to get out of control. So did [Rhys Goodwin’s] coffee maker hack. What started as a little restoration project of a second-hand coffee machine resulted in a complete upgrade to state of the art coffee brewing technology.

The Brasilia Lady comes with a 300 ml brass boiler, a pump and four buttons for power, coffee, hot water and steam. A 3-way AC solenoid valve, wired directly to the buttons, selects one of the three functions, while a temperamental bimetal switch keeps the boiler roughly between almost there and way too hot.

To reduce the temperature swing, [Rhys] decided to add a PID control loop, and on the way, an OLED display, too. He designed a little shield for the Arduino Nano, that interfaces with the present hardware through solid state relays. Two thermocouples measure the temperature of the boiler and group head while a thermal cut-off fuse protects the machine from overheating in case of a malfunction.

Also, the Lady’s makeup received a complete overhaul, starting with a fresh powder coating. A sealed enclosure along with a polished top panel for the OLED display were machined from aluminum. [Rhys] also added an external water tank that is connected to the machine through shiny, custom lathed tube fittings. Before the water enters the boiler, it passes through a custom preheater, to avoid cold water from entering the boiler directly. Not only does the result look fantastic, it also offers a lot more control over the temperature and the amount of water extracted, resulting in a perfect brew every time. Enjoy [Rhys’s] video where he explains his build:

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Interactive WeddingBots Built Into Nespresso Capsules

July 1, 2016 by Moritz Walter 2 Comments

Today is a very special day for [Mandy and Sebastian], as they conclude the sacred solder joint of marriage. We send our sincerest congratulations and best wishes to the bridal couple, and can’t help but envy the guests of their ceremony, who received a very special wedding favor: A WeddingBot.

For their wedding party, [Mandy and Sebastian] created a little game on their own (translated). Each guest would receive a unique, little WeddingBot. Each of these is individually tailored for a certain guest and features a fitting look, a characteristic behavior and would play a special melody or jingle meaningful to this guest. However, the guests don’t get their WeddingBot, they get the WeddingBot of another guest – and the challenge to find this guest on the party. Guests would then exchange their WeddingBots, which also makes a great occasion to introduce themselves to each other. If the clues given by the WeddingBots themselves would not suffice to find the right owner, guest could place a WeddingBot on a clue station, which then would provide further hints by displaying images, texts or even riddles.

The design is based on the ATtiny45 microcontroller, with LEDs for the eyes, a light sensor, and a piezo disc for the sound as the main components. As an enclosure, they chose to repurpose empty Nespresso® capsules, which look nice and adds volume to the PCBs. The smiley face silk screen on the PCBs was then individualized with a black marker and packed in a beautiful hand-crafted box. The little fellows communicate with the Raspberry Pi based clue station by flashing their LEDs in a certain pattern. A light sensor hooked up to the Pi lets the station identify the bot and display the corresponding clue on a screen. Check out the video below to see how it works:

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Hackaday Prize Entry: Invisible

June 29, 2016 by Moritz Walter 20 Comments

[Kate Reed] found a quote by a homeless person that said “No one sees us”, which led her to exploring what it actually means to be invisible — and if we actually choose to be invisible by hiding away our emotions, sexual preference, race or income. She realized that too often, we choose to only see what we want to see, rendering all the rest invisible by looking away. Her public art campaign and Hackaday Prize entry “Invisible” aims to increase social awareness and strengthening the community by making hidden thoughts, feelings and needs visible.

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