A Gloriously Impractical Electromechanical Display

December 19, 2017 by Tom Nardi 28 Comments

For this year’s office holiday party, [Gavan Fantom] wanted to do something really special. Coworkers were messing with LEDs to come up with displays and decorations, but they lack that old-school feel of mechanical displays. He wanted to create something that had retro look of moving elements, but didn’t want to just recreate the traditional flip mechanism we’ve all seen over and over.

The mechanism to drive a single “pixel”.

What [Gavan] came up with is breathtakingly impractical 8×8 display that sounds as cool as it looks. Each “pixel” in the display is a 3D printed screw mechanism rotated by a hobby servo. As the pixel is rotated in its case, it becomes progressively more visible to the observer. The opacity of the pixel can even be adjusted by varying the degree of rotation, allowing for rudimentary display of grayscale images.

Each element in the display is made up of seven 3D printed parts and two nails, which the mechanism slides on to move forward and backward. An 8×8 display needs 64 elements, which means the entire display needs 64 servos, 128 nails, and a whopping 448 3D-printed parts. Even with two printers attacking the production in parallel, the printing alone took over two weeks to complete.

The display is powered by a Raspberry Pi and three “Mini Maestro” controllers which can each handle 24 servos. [Gavan] found some sample code in Python to pass commands to the Maestro servo controllers, which he used as a template when writing his own software. The Python script opens image files, converts them to grayscale, and then maps the value of each pixel to rotation of the corresponding servo. He says the software is a little rough and that there’s still some calibration to be done, but we think the results are phenomenal so far.

Mechanical displays are a favorite of hackers, due in no small part to the awesome noises they make while in operation. While we’ve seen some very creative approaches to this type of display before, what [Gavan] has created here is certainly in a league of its own.

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Geocache Locator Is The Gift That Keeps On Giving

December 18, 2017 by Tom Nardi 5 Comments

Depending on how you look at things, the holidays could be seen as either an excuse to spend money or an excuse to get creative. We imagine many Hackaday readers would rather head to their workbench than the mall when it comes time for gift giving, and [Sean Hodgins] is no different. He came up with the idea of hiding geocaches around his nephew’s neighborhood and building him a locator device to find them. The locator itself is intended to grow with his nephew, allowing him to reprogram it or use its parts for something completely different down the road.

The main components tucked inside of the 3D printed case of the locator are an Adafruit Trinket, a GPS receiver, and a compass module. The Adafruit NeoPixel Ring is of course front and center, serving as the device’s display. To power the device there’s an old battery, a LiPo charger circuit, and a 5V converter.

One of the goals for the project was that it could be constructed out of things [Sean] already had laying around, so some concessions had to be made. The Trinket ended up having too few pins, the compass lacks an accelerometer, and the switches and buttons are a bit clunky for the build. But in the end it comes together well enough to get the job done, and at least he was able to clear some stuff out of his parts bins.

To allow its owner to disassemble and potentially rebuild it into something else later, no soldered joints were used in the construction of the locator. Everything is done with jumper wires, which lead to some interesting problem solving such as using a strip of pin header as a bus bar of sorts. A bit of heat shrink over the bundle holds everything together and prevents shorts.

Location-aware gadgets happen to be an extremely popular gift choice among the hacker crowd. We’ve covered everything from devices cobbled together from trash to hardware which could pass for a commercial product.

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Frankendrones: Toy Quads With A Hobby Grade Boost

December 18, 2017 by Tom Nardi 3 Comments

If you’re not involved in the world of remote controlled vehicles, you may not know there’s a difference between “toy” and “hobby” grade hardware. For those in the RC community, a toy is the kind of thing you’ll find at a big box store: cheap, works OK, but lacking in features and build quality. On the other hand, hobby hardware is generally considered to be of higher quality and performance, as well as being more modular. At the risk of oversimplification: if you bought it ready to go from a store it’s probably a toy, and if you built it from parts it would generally be considered hobby grade.

But with the rock bottom prices of toy quadcopters, that line in the sand is having a harder time than ever holding some in the community back. The mashup of toy and hobby grade components is giving rise to the concept of “frankendrones” that combine the low cost of toy hardware with key upgrades from the hobby realm. Quadcopter blogger [garagedrone] has posted a roundup of modifications made to the Bayangtoys X16, a $99 quadcopter which is becoming popular in the scene.

Some of the modifications are easy enough for anyone to do. Swapping out the original propellers for ones meant for the DJI Phantom 3 increases performance and doesn’t even require tools. If you want to go a bit further down the rabbit hole, you can cut off the X16’s battery connector and replace it with a standard XT60. That lets you use standard 3S LiPo batteries, which are cheaper and higher capacity than the proprietary ones the toy shipped with.

If you have a 3D printer, there are also a number of upgraded parts you can print which will bolt right onto the X16. Payload adapters, landing gear, and GoPro mounts are all just a few clicks (and some filament) away. This library of 3D printable parts is made possible in part because the X16’s frame is itself a clone of another toy quadcopter, the popular Syma X8C. So anything listed as compatible with the Syma X8C should work with the X16 (and vice versa).

Finally, if you really want to take the X16 to the next level, you can swap out the flight controller with an open source and better supported hobby grade model. Some of these flight controllers and associated new receivers can end up costing about half as much as the X16 did to begin with, but the vast improvement in performance and capability should more than make up for the cost.

We’ve covered previous efforts to increase the performance of low cost quadcopters in the past, as well as builds that put frugality front and center. It seems that no matter what your budget is a screaming angel of death is available if you want it.

Thanks to [Calvin] for the tip.

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3D Printing The Final Frontier

December 18, 2017 by Tom Nardi 29 Comments

While down here there’s room for debate about the suitability of 3D printing for anything more serious than rapid prototyping, few would say the same once you’ve slipped the surly bonds of Earth. With 3D printing, astronauts would have the ability to produce objects and tools on-demand from a supply of inert raw building materials. Instead of trying to pack every conceivable spare part for a mission to Mars, replacements (assuming a little forward thinking on the part of the spacecraft designers) can be made to order out of the stock of raw plastic or metal kept on-board. The implications of such technology for deep space travel or off-world settlement simply cannot be overstated.

In the more immediate future, 3D printing can be used to rapidly develop and deploy unmanned spacecraft. Tiny satellites (referred to as CubeSats) could be printed, assembled, and deployed by astronauts already in orbit. Innovations such as these could allow science missions to be planned and executed in months instead of years, and at a vastly reduced cost.

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Machined Lightsaber Pen For A More Civilized Age

December 18, 2017 by Tom Nardi 13 Comments

In an increasingly paperless society, writing implements are becoming an obsolete technology for many of us. Certainly not the kind of thing the average person would think to spend more than a couple bucks on, to say nothing of machining one out of a solid piece of aluminum bar stock. But clearly [Bob] is not most people. He recently dropped us a line about a video he uploaded to his aptly-named YouTube channel “Making Stuff”, where he goes through the steps required to turn raw materials into a writing instrument worthy of a Jedi.

Starting with a piece of aluminum chucked up in the lathe, [Bob] cuts out the iconic ribbed profile of Luke’s saber and fills in the gaps with nothing more exotic than a black Sharpie. He then moves on to the more complex shape of the emitter, and then flips the handle over in the lathe and hollows it out so a brass tube can be inserted.

Somewhat surprisingly, it seems more effort ends up being put into the acrylic “blade” than the aluminum handle itself. A chunk of acrylic is drilled and tapped so that it can be mounted in the chuck, and then turned down into a long cylinder. A tip is then cut in the end, the length of the blade is hollowed out, and finally it gets polished up to a nice shine.

The build is completed by inserting a standard ink pen cartridge down the center of the now completed saber. Surely the pen aficionados will lament that he didn’t attempt to build his own ink cartridge as well, but we think he gets a pass considering the rest of it was made from scratch.

If even a glorious writing instrument such as this isn’t enough to get you to re-learn how to write your name, fear not. Whether you’re making music or capturing flags, we’ve played home to numerous other saber projects; eye-safe or otherwise.

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DIY Cable Chain Looks Great, Stays Cheap

December 17, 2017 by Tom Nardi 50 Comments

If you’ve built a 3D printer, CNC, laser cutter, or basically any piece of electrical equipment that moves around, then you’ve run into the problem of securing the bundle of wires that such machines always require. The easy way out is to zip tie them all up into a tight harness or put them in commercially available wraps or sleeves, but these don’t really impart any mechanical strength on the wires. With repetitive motion it’s not unheard of to break a conductor or two, causing intermittent failures and generally leading to a painful diagnostic session trying to isolate the broken wire.

An alternative are what are generally referred to as “cable chains”. These are rigid enclosures for your wiring that not only keep things tidy, but give the wires the mechanical support necessary to prevent fatigue. Unfortunately, they are often many times more expensive than a simple wire wrap or pack of zip ties. But [Brad Parcels] has written into our tip line to share with us a sort of hybrid approach to wire management that has many of the same advantages as a traditional cable chain, but at a greatly reduced cost.

The key to the design is using the metallic tape from a cheap tape measure to give the bundle of wires some mechanical strength. As anyone who’s ever played around with a tape measure knows, if you bend the tape over into a U shape it will hold the bend even if you extend and retract it. Thanks to this principle, [Brad] realized that all he need to do was add some wire sleeves and he would have a cheap and effective way to keep his wiring neat and sag-free.

[Brad] punches holes in the tape to secure it to his 3D printed mounting arms, but really any method of securing the tape to the frame of your machine will work just as well. He then slides a cable sleeve over the tape itself to protect from any possibility of the edge of the tape nicking a wire, and then finally a larger wire sleeve over the entire assembly.

After running the wires between the two sleeves, heatshrink can be used on the ends to neatly close everything up. Just make sure you remember all your wires before you seal it, [Brad] learned that one the hard way. But overall, he reports this DIY cable chain arrangement has been working wonderfully in his machine, providing smooth and silent movement for only a few bucks.

Cable management for projects that move is one of those things that doesn’t always get the attention it deserves. Not only can it keep your project looking professional, but it just might save you some time down the road by preventing failures.

Turning Saw Blades Into Throwing Stars

December 15, 2017 by Tom Nardi 12 Comments

The holidays are nearly upon us, and if you haven’t found the perfect gift for the Mall Ninja in your life yet, this latest hack might be just what you’re looking for. On his YouTube channel, [The Nocturnal Alchemist] demonstrates how to make ninja throwing stars (shuriken) out of an old circular saw blade. One could probably argue that a circular saw itself is close enough to throwing star if your only goal is to wreck some stuff in your backyard, but with this method they’ll have that official samurai look.

To start the process, he hits both sides of the circular saw blade with a grinder to smooth out the surface. He then traces the desired star shapes onto the blade, and cuts the blade into pieces so it’s easier to manage. The rough shape of the stars is cut out with an angle grinder, and a belt sander lets him sharpen the edges.

At this point the stars are effectively finished, but if you want something that’s going to look good on the shelf next to the katana you bought online, you need to do some more finish work. He sands both sides of the stars by hand, starting at 80 grit and working all the way up to 1200 grit wet paper. Once sanded, paste wax is rubbed in with a cloth to give it a protective coating.

With the finish work done, all that’s left to do is throw your new shuriken at cans of soda and watermelons as a demonstration of their power. To this end, he has come prepared with a 1,000 FPS camera; so if you’ve ever wanted to see cans of off-brand soda getting exploded with a throwing star, your Mall Ninja friend isn’t the only one about to get a gift.

With circular saw blade shuriken completed, all you’ll need to do to complete your urban samurai transformation is forge yourself a sword, and perfect your run in virtual reality.

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