Custom Inflatables Are Only A Laser Beam Away

April 2, 2019 by Tom Nardi 26 Comments

Carl Sagan one said “If you wish to make an apple pie from scratch, you must first invent the universe.” It might not be a very accurate description of the relative difficulty level of baking, but the logic is sound enough: there’s often a lot of ground work that needs to be to covered before you hit your ultimate goal. A perfect example of this principle is the inflatable raft that [ralph124c] hopes to eventually create; before he can set sail he has to perfect making balloon animals with his laser cutter.

In the long run, the raft will be constructed from sheets of TPU coated fabric that are fused together with a hot iron. But before he spends the time and money on building the real thing, he wants to do some scaled down tests to make sure his design works as expected. He makes a cryptic remark about learning the hard way that inflatables are prone to bouts of strange behavior, and out of an overabundance of caution we’ll just take his word for it.

He hoped to test his designs with the much cheaper LDPE film, but he found that the hot iron didn’t fuse it together in the way he was hoping. His mind turned to his 60 watt laser cutter, and wondered if the desired effect could be achieved by turning the power down as low as possible and quickly moving across the material.

His first attempts either blew right through the film or did absolutely nothing, but eventually he had the bright idea to move the laser farther from the LDPE. This put the beam out of focus, which not only expanded the area it would cover, but reduced the energy being delivered to the surface. With a bit more experimentation, he found he was able to neatly weld the pieces of material together. He even found that he could increase the power slightly to cut through the film without having to adjust the laser focus. With the ability to create complex inflatable shapes, perhaps [ralph124c] will create balloon version of Carl Sagan or an apple pie to celebrate.

Of course, this technology isn’t limited to birthday balloons and model rafts. The ability to quickly and easily produce custom inflatable shapes could be a huge boon to anyone working in soft robotics, and we’ve even seen similar concepts applied to haptic feedback systems.

[Thanks to Arthur for the tip.]

The Only Cassette Player Worth Owning In 2019

April 2, 2019 by Tom Nardi 73 Comments

Vinyl has the audiophiles to keep it relevant, and CDs still have the people who are scared of streaming music, but who mourns for the cassette tape? Yesterday we would have said nobody, but now that [Igor Afanasyev] has unleashed his latest creation onto an unsuspecting world, we aren’t so sure anymore. A portable tape player that started as a $5 find from the Goodwill is now an outrageously gorgeous piece of electronic art thanks to 3D printing and a liberal application of LEDs.

After freeing the tape mechanism from the original enclosure and extraneous electronics like the AM/FM tuner, [Igor] got to work designing a retro styled enclosure for the hardware which would show off the complex electromechanical bits which would traditionally be hidden. With the addition of a clever 3D printed holder, he was even able to add microswitches under the original player’s buttons so he could detect the player’s current state without having to modify the electronics. This lets the finished player change the color of the RGB LEDs based on what it’s currently doing.

[Igor] came up with a very clever way of integrating light-up icons into the case by placing bright LEDs behind specially crafted thin sections of the print. It looked awesome in his tests, but after the considerable sanding, priming, and painting it took to turn the 3D printed parts into a production-quality enclosure, the LEDs are no longer visible on the final product. Even though they didn’t work in this particular case, we think it’s a brilliant technique worthy of ~~stealing~~ further research.

The detail that [Igor] but into this build is phenomenal. Seeing all the individual components he had to design and print to make the final product come together is really nothing short of inspirational. Projects like these are where 3D printing really shines, as trying to replicate this build with traditional manufacturing techniques would be an absolute nightmare.

If you can’t quite shake the feeling that you’ve seen this name or attention to detail before, it’s for good reason. Last year we covered another build showing the knack [Igor] has for turning the ordinary into the extraordinary.

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A Scratch Built VFD Clock With Inner Beauty

March 29, 2019 by Tom Nardi 5 Comments

Vacuum fluorescent displays (VFDs) are one of those beautiful pieces of bygone technology that you just don’t see much of anymore. At one time they were a mainstay of consumer electronics, but today they’ve largely been replaced with cheaper and more energy efficient displays such as LEDs and LCDs. While they might be objectively better displays, we can’t help but feel a pang of regret seeing a modern kitchen bereft of that unmistakable pale green glow.

If his impressive VFD clock is any indication [Simón Berraud] feels the same way. Not only does the clock’s display instantly trigger waves of nostalgia, but the custom PCB has that mistakable look of consumer electronics circa 1985. If we didn’t know better, we’d think this thing fell through a time warp.

Well, if it wasn’t for the SMD ATmega328 on the flip side of the board, anyway. In addition to the MCU, the clock features four ULN2003AN Darlington transistor arrays to drive the VFD, and a M48T08 Real Time Clock to keep the whole thing ticking.

The careful observer might notice a distinct lack of buttons or switches on the clock, and wonder how this retro wonder is set. In a particularly radical hack, [Simón] sets the time with a hard coded variable in the source code; you just need to set it far enough into the future so that you have enough time to power it up at the appropriate moment.

[Simón] has put the Arduino-flavored source code for the ATmega328 as well as the schematics and board files in his GitHub repository for anyone else who might want to take a walk down memory lane. While you’re at it, you may want to look at these tips for getting unknown VFDs up and running, as well as this interesting explanation of how they can be used as amplifiers if you’re really looking for style points.

[Caleb Kraft] Brings Us The Moon, On A Budget

March 29, 2019 by Tom Nardi 17 Comments

As you might expect from one of our most illustrious alumni, [Caleb Kraft] is a rather creative fellow. Over the years he’s created some absolutely phenomenal projects using CNC routers, 3D printers, laser cutters, and all the other cool toys the modern hacker has access to. But for his latest project, a celebration of the full Moon, he challenged himself to go low-tech. The Moon is something that anyone on Earth can look up and enjoy, so it seemed only fitting that this project should be as accessible to others as possible.

[Caleb] started this project by looking for high-resolution images of the Moon, which was easy enough. He was even able to find sign shops that were more than happy to print a giant version for him. Unfortunately, the prices he was quoted were equally gargantuan. To really be something that anyone could do, this project needed to not only be easy, but as affordable as possible. But where do you get a giant picture of the Moon for cheap?

He eventually found a source for Moon shower curtains (we told you he was creative), which fit the bill perfectly. [Caleb] says they aren’t nearly as detailed as the original images he found, but unless you’ve got your face pressed up against it you’ll never notice anyway. To make the round frame, he used PEX tubing from the hardware store and simply stapled the curtain directly to the soft plastic. The hardest part of the whole project is arguably getting the curtain flat and taut on the PEX ring.

Technically you could stop now and have a pretty slick piece of art to hang on your wall, but [Caleb] took the idea a bit farther and put a strip of RGB LEDs along the inside of the ring. The shower curtain material does a decent enough job of diffusing the light of the LEDs to make it look pretty good, though there’s certainly some room for improvement if you want to get a more even effect over the entire surface. While you’re at it, you might as well add in some additional electronics so the lighting matches the current phase of the real-life Moon.

On the other hand, if you’re willing to settle for a far more diminutive version of Luna and don’t mind using those highfalutin hacker tools that [Caleb] decided to avoid for the good of mankind, we’ve got a project you might be interested in.

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Finding Plastic Spaghetti With Machine Learning

March 29, 2019 by Tom Nardi 10 Comments

Among 3D printer owners, “spaghetti” is the common term for the tangled mess of stringy plastic that’s often the result of a failed print. Fear of their print bed turning into a hot plate of PLA spaghetti is enough to keep many users from leaving their machines operating overnight or while they’re out of the house. Accordingly, we’ve seen a number of methods that allow the human operator to watch their print remotely to make sure everything is progressing smoothly.

But unless you plan on keeping your eyes on your phone the entire time you’re out of the house, there’s still a chance some PETG pasta might sneak its way out. Enter the Spaghetti Detective, an open source project that lets machine learning take over when you can’t sit watching the printer all day. Their system plugs into Octoprint to monitor your print in real-time and pause it if it starts looking particularly stringy. The concept is still under development, but judging by the gallery of results submitted by users, the system seems to have a knack for identifying non-edible noodles.

Once the software comes out of beta it looks like the team is going to try to monetize it by providing hosting and monitoring services for a monthly fee, but as it’s an open source project, you’re also able to run the software on your own machine. Though the documentation notes that the lowly Raspberry Pi doesn’t have quite what it takes to handle the image recognition routines, so you’ll need a proper computer if you want to self-host the service. Could be a good use for that old laptop you’ve got kicking around the lab.

As demonstrated in the video after the break, the system’s “spaghetti confidence” is shown with a simple to understand gauge: green is a good-looking print, and red means the detective is getting a sniff of the stringy stuff. If your print dips into the red too much, Octoprint is commanded to pause the print. The user can then look at the last image from the printer and decide to either cancel the print entirely, or resume if the Spaghetti Detective got a little overzealous.

Frankly, it’s a brilliant idea and we’re very interested to see where it goes from here. Assuming you’ve got Octoprint controlling your 3D printer there are some very clever monitoring systems out there currently, but since spaghetti isn’t the only thing a rogue 3D printer can cook up, having an extra line of defense sounds like a good idea to us.

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Ammo Can Holds A 14,000 Lumen LED Flashlight

March 28, 2019 by Tom Nardi 10 Comments

For most people, a flashlight is just something you keep in a drawer in the kitchen in case the power goes out. There’s even a good chance your “flashlight” is just an application on your phone at this point. But as we’ve seen many times before from mechanical keyboards to Power Wheels, hardcore niche communities can develop around the most innocuous pieces of hardware; and the lowly flashlight is no different.

Case in point, this 14,000 lumen LED flashlight built by [Bryson Hicks]. Designed around a 100 watt module from Stratus LED, the flashlight uses a number of 3D printed components to make itself at home in a suitably hardcore enclosure: a metal ammo can. With the addition of some modular electronics and a rather slick little control panel, his light is ready to deliver an unreasonable level of brightness anywhere he wishes.

The Stratus LED module includes its own driver, and just needs to be hooked up to a suitably beefy power source to do its thing. [Bryson] went with a 4500 mAh LiPo battery that he says gets him about a one hour runtime at full brightness. For somewhat less intense operation, he’s added a potentiometer which interfaces with the module’s driver board to control the LED output. Considering how fast the light sucks down the juice, adding a small LCD battery charge indicator to the top of the device seems like it was a prudent decision.

To prevent you from cooking anyone’s eyes at close range, the light requires you to first “arm” it by flipping the military style protected switch. Once the switch is in the on position, an illuminated push button is used to actually turn the LED module on and off. You can also snap the toggle switch back into the closed and covered position if you needed to kill the light in a hurry.

This isn’t the first preposterously bright LED flashlight we’ve seen around these parts. There’s something of an arms-race between hackers and makers to develop increasingly bright lights they can carry around, on the off chance they need to illuminate an entire neighborhood.

WOPR: Security Loses Some Of Its Obscurity

March 28, 2019 by Tom Nardi 11 Comments

As we’ve seen time and time again, the word “hacker” takes on a different meaning depending on who you’re talking to. If you ask the type of person who reads this fine digital publication, they’ll probably tell you that a hacker is somebody who likes to learn how things work and who has a penchant for finding creative solutions to problems. But if you ask the average passerby on the street to describe a hacker, they might imagine somebody wearing a balaclava and pounding away at their laptop in a dimly lit abandoned warehouse. Thanks, Hollywood.

Naturally, we don’t prescribe to the idea of hackers being digital villains hell-bent on stealing your identity, but we’ll admit that there’s something of rift between what we call hacking versus what happens in the information security realm. If you see mention of Red Teams and Blue Teams on Hackaday, it’s more likely to be in reference to somebody emulating Pokemon on the ESP32 than anything to do with penetration testing. We’re not entirely sure where this fragmentation of the hacking community came from, but it’s definitely pervasive.

In an attempt bridge the gap, the recent WOPR Summit brought together talks and presentations from all sections of the larger hacking world. The goal of the event was to show that the different facets of the community have far more in common than they might realize, and featured a number of talks that truly blurred the lines. The oscilloscope toting crew learned a bit about the covert applications of their gadgets, and the high-level security minded individuals got a good look at how the silicon sausage gets made.

Two of these talks which should particularly resonate with the Hackaday crowd were Charles Sgrillo’s An Introduction to IoT Penetration Testing and Ham Hacks: Breaking into Software Defined Radio by Kelly Albrink. These two presentations dealt with the security implications of many of the technologies we see here at Hackaday on what seems like a daily basis: Bluetooth Low Energy (BLE), Software Defined Radio (SDR), home automation, embedded Linux firmware, etc. Unfortunately, the talks were not recorded for the inaugural WOPR Summit, but both presenters were kind of enough to provide their slides for reference.

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