Axial 3D Printer Aces Test Aboard Virgin Spaceplane

July 13, 2024 by Tom Nardi 32 Comments

Here on Earth, being able to 3D print replacement parts is handy, but rarely necessary. If you’ve got a broken o-ring, printing one out is just saving you a trip to the hardware store. But on the Moon, Mars, or in deep space, that broken component could be the difference between life and death. In such an environment, the ability to print replacement parts on demand promises to be a game changer.

Which is why the recent successful test of a next-generation 3D printer developed by a group of Berkeley researchers is so exciting. During a sub-orbital flight aboard Virgin Galactic’s Unity spaceplane, the SpaceCAL printer was able to rapidly produce four test prints using a unique printing technology known as computed axial lithography (CAL).

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Supercon 2023: Why More Hackers Should Earn Their Wings

July 10, 2024 by Tom Nardi 14 Comments

Hacking has taken on many different meanings over the years, but if you’re here reading these words, we’ll assume your definition is pretty close to ours. To hack is to explore and learn, to find new and (hopefully) better ways of doing things. Or at least, that’s part of it. The other part is to then take what you learned and share it with others. Do that enough, and soon you’ll find yourself part of a community of like-minded individuals — which is where things really start getting interesting.

Here at Hackaday the objects of our attention are, with the occasional exception, electronic devices of some sort or another. Perhaps an old piece of gear that needs a modern brain transplant, or a misbehaving consumer gadget that could benefit from the addition of an open source firmware. But just as there are different ways to interpret the act of hacking, there’s plenty of wiggle room when it comes to what you can hack on.

In his talk during the 2023 Hackaday Supercon, Tom Mloduchowski makes the case that more hackers should be getting involved with aviation. No, we’re not talking about flying drones, though he does cover that during the presentation. This is the real deal. Whether you want to take a quick joyride in a small plane, become a professional pilot, or even build and operate your own experimental aircraft, this talk covers it all.

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Full-Scale Flying DeLorean Gets Closer To Liftoff

July 6, 2024 by Tom Nardi 11 Comments

These days, even hobbyist multi-rotor aircraft are capable of carrying considerable payloads. For example, the test rig that [Brian Brocken] recently put together should be able to loft more than 80 pounds (36 kilograms) without breaking a sweat. That would be a whole lot of camera gear or other equipment, but in this case, he’s planning on carrying something a bit more interesting: a full-scale foam DeLorean.

We first covered this project in December of last year, when [Brian] started using a massive robotic arm to carefully cut the body and individual parts of the car out of expanded polystyrene foam. He estimated at the time the body should weigh in at less than 30 lbs (14 kg), so he’d need to build a quadcopter with a maximum lift of roughly twice that much to keep the performance where he wanted it.

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Building An IR Thermometer That Fits On Your Keychain

July 5, 2024 by Tom Nardi 11 Comments

Non-contact infrared (IR) thermometers used to be something of an exotic tool, but thanks at least in part due to the COVID-19 pandemic, they’re now the sort of thing you see hanging up near the grocery store checkout as a cheap impulse buy. Demand pushed up production, and the economies of scale did the test. Now the devices, and the sensors within them, are cheap enough for us hackers to play with.

The end result is that we now have projects like this ultra compact IR thermometer from [gokux]. With just a handful of components, some code to glue it all together, and a 3D printed enclosure to wrap it all up, you’ve got a legitimately useful tool that’s small enough to replace that lucky rabbit’s foot you’ve got on your keys.

If this project looks familiar, it’s because the whole thing is closely related to the LiDAR rangefinder [gokux] put together last month. It shares the same Seeed Studio XIAO ESP32-C3 microcontroller, 0.49 inch OLED display, and tiny 40 mAh LiPo battery. The only thing that’s really changed, aside from the adjustments necessary to the 3D printed enclosure, is that the LiDAR sensor was replaced with a MLX90614 IR temperature sensor.

[gokux] has put together some great documentation for this build, making it easy for others to recreate and remix on their own. Assembly is particularly straightforward thanks to the fact that both the display and temperature sensor communicate with the ESP32 over I2C, allowing them to be wired daisy chain style — there’s no need for even a scrap of perfboard inside the case, let alone a custom board.

Hackaday Podcast Episode 278: DIY Subs, The ErgoRing, And Finding NEMA 17

July 5, 2024 by Tom Nardi 3 Comments

In this episode, Hackaday Editors Elliot Williams and Tom Nardi kick things off with a reminder about the impending deadline for Supercon talk and workshop proposals. From there discussion moves on to the absolutely incredible tale of two brothers who solved a pair of missing person cases with their homebrew underwater vehicle, false data sneaking into OctoPrint’s usage statics, and an organic input device that could give the classic mouse a run for its money.

You’ll also hear about cheap radar modules, open source Xbox mod chips, and lawnmowers from the grocery store. The episode wraps up with a look at the enduring mystique of perpetual motion devices, and the story of a legendary ship that might soon end up being turned into paper clips.

Check out the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

As always, this week’s episode is available as a DRM-free MP3.

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Toyota Heater Switches Learn New Tricks

July 5, 2024 by Tom Nardi 32 Comments

The look, the feel, the sound — there are few things more satisfying in this world than a nice switch. If you’re putting together a device that you plan on using frequently, outfitting it with high-quality switches is one of those things that’s worth the extra cost and effort.

So we understand completely why [STR-Alorman] went to such great lengths to get the aftermarket seat heaters he purchased working with the gorgeous switches Toyota used in the 2006 4Runner. That might not sound like the kind of thing that would involve reverse engineering hardware, creating a custom PCB, or writing a bit of code to tie it all together. But of course, when working on even a halfway modern automobile, it seems nothing is ever easy.

The process started with opening up the original Toyota switches and figuring out how they work. The six-pin units have a lot going on internally, with a toggle, a rheostat, and multiple lights packed into each one. Toyota has some pretty good documentation, but it still took some practical testing to distill it down into something a bit more manageable. The resulting KiCad symbol for the switch helps explain what’s happening inside, and [STR-Alorman] has provided a chart that attributes each detent on the knob with the measured resistance.

But understanding how the switches worked was only half the battle. The aftermarket seat heaters were only designed to work with simple toggles, so [STR-Alorman] had to develop a controller that could interface with the Toyota switches and convince the heaters to produce the desired result. The custom PCB hosts a Teensy 3.2 that reads the information from both the left and right seat switches, and uses that to control a pair of beefy MOSFETs. An interesting note here is the use of very slow pulse-width modulation (PWM) used to flip the state of the MOSFET due to the thermal inertia of the heater modules.

We love the effort [STR-Alorman] put into documenting this project, going as far as providing the Toyota part numbers for the switches and the appropriate center-console panel with the appropriate openings to accept them. It’s an excellent resource if you happen to own a 4Runner from this era, and a fascinating read for the rest of us.

A Second OctoPrint Plugin Has Been Falsifying Stats

July 4, 2024 by Tom Nardi 34 Comments

The ongoing story of bogus analytical data being submitted to the public OctoPrint usage statistics has taken a surprising turn with the news that a second plugin was being artificially pushed up the charts. At least this time, the developer of the plugin has admitted to doing the deed personally.

Just to recap, last week OctoPrint creator [Gina Häußge] found that somebody had been generating fictitious OctoPrint usage stats since 2022 in an effort to make the OctoEverywhere plugin appear to be more popular than it actually was. It was a clever attempt, and if it wasn’t for the fact that the fake data was reporting itself to be from a significantly out of date build of OctoPrint, there’s no telling how long it would have continued. When the developers of the plugin were confronted, they claimed it was an overzealous user operating under their own initiative, and denied any knowledge that the stats were being manipulated in their favor.

Presumably it was around this time that Obico creator [Kenneth Jiang] started sweating bullets. It turns out he’d been doing the same thing, for just about as long. When [Gina] contacted him about the suspicious data she was seeing regarding his plugin, he owned up to falsifying the data and published what strikes us as a fairly contrite apology on the Obico blog. While this doesn’t absolve him of making a very poor decision, we respect that he didn’t try to shift the blame elsewhere.

That said, there’s at least one part of his version of events that doesn’t quite pass the sniff test for us. According to [Kenneth], he first wrote the script that generated the fake data back in 2022 because he suspected (correctly, it turns out) that the developers of OctoEverywhere were doing something similar. But after that, he says he didn’t realize the script was still running until [Gina] confronted him about it.

Now admittedly, we’re not professional programmers here at Hackaday. But we’ve written enough code to be suspicious when somebody claims a script they whipped up on a lark was able to run unattended for two years and never once crashed or otherwise bailed out. We won’t even begin to speculate where said script could have been running since 2022 without anyone noticing…

But we won’t dwell on the minutiae here. [Gina] has once again purged the garbage data from the OctoPrint stats, and hopefully things are finally starting to reflect reality. We know she was already angry about the earlier attempts to manipulate the stats, so she’s got to be seething right about now. But as we said before, these unfortunate incidents are ultimately just bumps in the road. We don’t need any stat tracker to know that the community as a whole greatly appreciates the incredible work she’s put into OctoPrint.