It’s Time For Direct Metal 3D-Printing

May 19, 2016 by Moritz Walter 75 Comments

It’s tough times for 3D-printing. Stratasys got burned on Makerbot, trustful backers got burned on the Peachy Printer meltdown, I burned my finger on a brand new hotend just yesterday, and that’s only the more recent events. In recent years more than a few startups embarked on the challenge of developing a piece of 3D printing technology that would make a difference. More colors, more materials, more reliable, bigger, faster, cheaper, easier to use. There was even a metal 3D printing startup, MatterFab, which pulled off a functional prototype of a low-cost metal-powder-laser-melting 3D printer, securing $13M in funding, and disappearing silently, poof.

This is just the children’s corner of the mall, and the grown-ups have really just begun pulling out their titanium credit cards. General Electric is on track to introduce 3D printed, FAA-approved fuel nozzles into its aircraft jet engines, Airbus is heading for 3D-printed, lightweight components and interior, and SpaceX has already sent rockets with 3D printed Main Oxidizer Valves (MOV) into orbit, aiming to make the SuperDraco the first fully 3D printed rocket engine. Direct metal 3D printing is transitioning from the experimental research phase to production, and it’s interesting to see how and why large industries, well, disrupt themselves.

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The Art And Science Of Bending Sheet Metal

May 18, 2016 by Moritz Walter 49 Comments

A motor mount. A sturdy enclosure. A 43.7° bracket. The average hack requires at least one angled metal part, and the best tool to make one is still the good ol’ press brake. Bending parts requires a few extra thoughts in the design and layout of the flat patterns, so if you want to know about bend allowances, bend deduction and how to bend accurate parts even without a press, read on.

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Hackaday Prize Entry: Powering A Pi From A Battery

May 11, 2016 by Moritz Walter 28 Comments

Knocking a microcontroller into sleep mode and waking it up on demand or in intervals is common practice in many low power applications, enabling devices to stay in operation for years on a single coin cell battery. Since there are tons of applications where you might want to do similar things with a Raspberry Pi, [Patrick Van Oosterwijck] created the LiFePO4wered/Pi. The module that snaps on to eight GPIO pins of a Pi, extending it by a long life LiFePO4 battery, a charging regulator, and a proper power management. Obviously, it also makes a great UPS.

[Patrick] realized this project by expanding his already available and equally useful LiFePO4wered/USB charging regulator module by a low power MSP430G2131 microcontroller and a load switch. A daemon on the Raspberry Pi speaks to the module over I2C, allowing you to schedule a wake-up timer, let your Pi autoboot after a power outage or just read out the current battery voltage through a command line tool. Once the Pi is safely shut down, the microcontroller will also go to sleep, resulting in a standby current of 8 uA for the whole system. Together with the 500 mAh LiFePo4 cell, that’s theoretically low enough to send your Pi-ncess into a seven-year-long sleep.

LiFePO4wered/Pi is not only good for sleeping, though. [Patrick’s] runtime tests show, that the 500 mAh cell will power a Raspberry Pi Zero and a WiFi dongle for about two hours. Because the Raspberry Pi and many USB peripherals won’t complain when only 3.2 V are present on the VBUS, [Patrick] was able to squeeze out even more runtime by dismissing the boost converter from the design and driving the Pi directly from the battery voltage. If that worries you, you can either read a detailed explanation on why that works so well or just have a look at the more compliant 5 V version.

Eventually, [Patrick] used his module to create a Raspberry Pi time-lapse camera. A little script lets the Pi take a picture on boot up, set a wake-up timer and go back to sleep again. Safely enclosed in a waterproof electric box and deployed into the wild, the camera took 120 pictures on a single charge.

We’re sure the module will find it’s way into many cool projects and we’re counting the hours until we can get one in [Patrick’s] tindie store. Until then, enjoy the time-lapse video:

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Hackaday Prize Entry: Raimi’s Bionic Arm

May 8, 2016 by Moritz Walter 9 Comments

Sometimes, the most amazing teams make the most wonderful things happen, and yet, there is just not enough time to finish all the features before the product ships. This is what happened to Raimi, who came to this world missing a right hand and half of her right forearm. Raimi is now 9 years old, and commercial mechatronic prostheses are still only available to those who can afford them. When Raimi’s father approached [Patrick Joyce] to ask him for help in building an affordable prosthesis, he knew it would matter, and went right to work.

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Meet Blue Jay, The Flying Drone Pet Butler

May 6, 2016 by Moritz Walter 18 Comments

20 students of the Eindhoven University of Technology (TU/e) in the Netherlands share one vision of the future: the fully domesticated drone pet – a flying friend that helps you whenever you need it and in general, is very, very cute. Their drone “Blue Jay” is packed with sensors, has a strong claw for grabbing and carrying cargo, navigates autonomously indoors, and interacts with humans at eye level.

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Can You Hear SamSat-218D?

May 5, 2016 by Moritz Walter 44 Comments

Students of the Samara State Aerospace University are having trouble getting a signal from their satellite, SamSat-218D. They are now reaching out to the radio amateur community, inviting everybody with sufficiently sensitive ~~UHF~~ VHF band (144 MHz) equipment to help by listening to SamSat-218D. The satellite was entirely built by students and went into space on board of a Soyuz-2 rocket on April 26, 2016. This is their call (translated by Google):

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Screw Drive Tractor Is About To Conquer Canada

May 5, 2016 by Moritz Walter 29 Comments

The incredible screw drive tractor is back. We’ve covered the previous test ride, which ended with a bearing pillow block ripping in half, but since then, again, a lot of repair work has been done. [REDNIC79] reinforced the load-bearing parts and put on a fresh pair of “tires”. The result is still as unbelievable as the previous versions, but it now propels itself forward at a blazing 3 mph (this time without tearing itself apart).

[REDNIC79] walks us through all the details of the improvements he made since the first version. After the last failure, he figured, that a larger screw pod diameter would give the vehicle a better floatation while smaller thread profile would prevent the screws from digging too deep into the ground, thus reducing the force required to move the vehicle forward.

[REDNIC79] found four identical 100 pounds, 16 inch diameter propane tanks to build the new pods from. The tanks were a bit too short for the tractor, so he cut open two of the tanks and used them to extend the other two before welding a double thread screw onto each. He also tapered the front ends of the tanks to make the ride even smoother. After mounting the new pods to the speedster, a pair of custom steel chain guards were added to prevent rocks from getting into the chain. And then, it was time for another test ride. Enjoy the video:

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