UV Resin Perfects 3D Print, But Not How You Think

January 4, 2022 by Tom Nardi 18 Comments

At this point, everyone knows that the print quality you’ll get from even an entry level UV resin printer far exceeds what’s possible for filament-based fused deposition modeling (FDM) machines. But there’s a trade-off: for the money, you get way more build volume by going with FDM. So until the logistics of large-format resin printers gets worked out, folks looking to make things like replica prop helmets have no choice but to put considerable time into post-processing their prints to remove the obvious layer lines.

But thanks to this somewhat ironic trick demonstrated by [PropsNstuff], you can actually use UV resin to improve the finish quality of your FDM prints. The idea is to put a layer of resin over the layer lines and other imperfections of the 3D print, cure it with a handheld UV flashlight, and then sand it smooth. Essentially it’s like using resin in place of a body filler like Bondo, with the advantage here being that the resin cures in seconds.

The thick resin fills in tough spots quickly.

Now to be clear, this isn’t a new idea. Our very own [Donald Papp] investigated the process back in 2018, and [Thomas Sanladerer] covered the idea in a video of his own the following year. But the difference here is that [PropsNstuff] doesn’t just coat the whole print with resin, he takes a more methodical approach. Working in small sections, he targets areas that really need the high-build properties offered by this technique.

With the tough spots addressed, he then moves on to coating larger areas with resin. But this time, he mixes leftover resin from his SLA printer with talcum powder to make a mix that can be brushed on without running everywhere. It takes a few thin coats, but with this mix, he’s able to build up large swaths of the print without losing any surface detail.

Is it still a hassle? Absolutely. But the final result does look spectacular, so until we figure out how to build the replicators from Star Trek, it looks like we’ll have to make up for our technological shortcomings with the application of a little elbow grease.

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Another Homebrew Linux Board Success Story

January 3, 2022 by Tom Nardi 26 Comments

It’s truly incredible what the hobbyist is now capable of. While it would have seemed all but impossible a few years ago, we’re happy to report that yet another dedicated hardware hacker has managed to spin up their own custom Linux single-board computer. Creator [Ian Kilgore] tells us the only goal when developing CATFOOD (yes, that’s the name) was to gain confidence with at-home board production, so it looks like a success to us.

To those who’ve been keeping an eye on this sort of thing, it will probably come as no surprise to hear [Ian] was inspired by the work of [Jay Carlson], who arguably kicked off this whole trend when he put together a bevy of homebrew Linux boards in an effort to compare different System-in-Package ICs. His incredibly detailed write-up of the experience and lessons learned along the way has emboldened other brave souls to take up the challenge.

The USB-C powered board uses an ARM i.MX 6ULL processor and features DDR3, NAND flash, and an Ethernet interface. That last one was the biggest deviation from the reference design, which meant it took a little fiddling to get right. For anyone playing along at home, [Ian] collected up the lessons learned while developing CATFOOD, bringing the whole learning experience full circle.

If you’re interested in more homebrew Linux SBCs, we’d highly recommend reading up on the WiFiWart developed by [Walker]. Over the course of about six months, we got to watch the open hardware board go from concept to a diminutive first prototype.

2021: As The Hardware World Turns

January 3, 2022 by Tom Nardi 15 Comments

Well, that didn’t go quite as we expected, did it? Wind the clock back 365 days, and the world seemed to be breathing a collective sigh of relief after making it through 2020 in one piece. Folks started getting their COVID-19 vaccines, and in-person events started tentatively putting new dates on the calendar. After a rough year, it seemed like there was finally some light at the end of the tunnel.

Turns out, it was just a another train. New variants of everyone’s favorite acute respiratory syndrome have kept the pandemic rolling, and in many parts of the world, the last month or so has seen more new cases of the virus than at any point during 2020. This is the part of the Twilight Zone episode were we realize that not only have we not escaped the danger, we didn’t even understand the scope of it to begin with.

Case in point, the chip shortages. We can’t blame it entirely on the pandemic, but it certainly hasn’t helped matters. From video game systems to cars, production has crawled to a standstill as manufacturers fight to get their hands on integrated circuits that were once plentiful. It’s not just a problem for industry either, things have gotten so bad that there’s a good chance most of the people reading this have found themselves unable to get their hands on a part or two these last few months. If you were working on a hobby project, it’s a temporary annoyance. But for those who planned on finally bringing their latest big idea to market, we’ve heard tales of heartbreaking delays and costly redesigns.

It would be easy to look at the last twelve months and see nothing but disappointment, but that’s hardly the attitude you want to have at the beginning of the year. So let’s take the high road, and look back on some of the highlights from 2021 as we turn a hopeful eye towards the future.

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Teensy 4 Pushed To The Limit With 1 GHz Overclock

January 2, 2022 by Tom Nardi 29 Comments

Do you need a microcontroller that runs at 1 GHz? No, probably not. But that didn’t stop [Visual Micro] from trying, and the results are pretty interesting. Not only did the plucky little chip not cook itself, it actually seemed to run fairly well; with the already powerful microcontroller getting a considerable boost in performance.

According to [Visual Micro] the Teensy 4.1, which normally has its ARM Cortex-M7 clocked at 600 MHz, can run at up to 800 MHz without any additional cooling. But beyond that, you’ll want to invite some extra surface area to the party. It’s easy enough to cut a chunk out of an old CPU/GPU cooler and stick it on with a dab of thermal compound, but of course there’s no shortage of commercially available heatsinks at this size that you could pick up cheap.

With the heatsink installed, [Visual Micro] shows the Teensy running at around 62 °C during a benchmark. If that’s a little hot for your liking, they also experimented with an old laptop cooler which knocked the chip down to an impressive 38 °C while under load. It doesn’t look like a particularly practical setup to us, but at least the option is there.

[Visual Micro] unfortunately doesn’t go into a lot of detail about the benchmark results, but from what’s shown, it appears the overclock netted considerable gains. A chart shows that in the time it took a stock Teensy to calculate 15.2 million prime numbers, the overclocked chip managed to blow through 21.1 million. The timescale for this test is not immediately clear, but the improvement is obvious.

Even at the stock 600 MHz, the Teensy 4 is a very powerful MCU. Especially after the 4.1 refresh brought in support for additional peripherals and more RAM. But we suppose some people are never satisfied. Got a project in mind that could benefit from an overclocked Teensy? We’d love to hear about it.

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An OpenSCAD Library For All Your CNC Cutting Needs

January 2, 2022 by Tom Nardi 16 Comments

While there’s always the edge case, there’s a strong likelihood that if you’re using OpenSCAD, you’re probably working on a CAD model that you intend to 3D print at some point. Of course that’s not to say this is all you can do in OpenSCAD, but it’s arguably what it does best. If you wanted to make artistic models, or maybe render what your new kitchen will look like, there are other tools better suited to such tasks.

But thanks to lasercut.scad, a library that [Brendan Sleight] has been working on for the last several years, we might have to reconsider our preconceived dimensional notions. Instead of designing parts for 3D printing, his library is all about creating parts intended for subtractive manufacturing. Originally (as the name implies) it was geared towards laser cutting, but the project has since evolved to support CNC routers, vinyl cutters, and pretty much anything else that can follow a DXF file.

The library has functions for creating the standard tricks used to build things from laser-cut pieces, like finger joints, captive nuts, and assembly tabs. If it was something you once saw holding together an old wooden 3D printer kit back in the day, you can probably recreate it with lasercut.scad. It even supports a pretty wild piece of rotational joinery, courtesy of [Martin Raynsford].

Don’t have a way of concentrating a sufficient number of angry photons at your workpiece? No worries. The library has since been adapted to take into account a parametric kerf width, which lets you dial in how much of a bite your particular tool will take from the material when it does the business. There are even special functions for dealing with very thin cuts, which [Brendan] demonstrates by assembling a box from sheet vinyl.

Of course, those who’ve used OpenSCAD will know there’s not an “Export for CNC” button anywhere in the stock interface. So to actually take your design and produce a file your cutter can understand, [Brendan] has included a Bash script that will run the necessary OpenSCAD incantations to produce a 2D DXF file.

[Brendan] decided to send this one in after he saw the aluminum enclosure OpenSCAD library we covered recently. If you’ve got your own pet project that bends some piece of hardware or software to your will, don’t be shy to let us know.

Taking A Close Look At Hawkeye’s Workbench

December 30, 2021 by Tom Nardi 51 Comments

We don’t have to tell you that the representation hackers and makers get in popular media is usually pretty poor. At this point, we’ve all come to accept that Hollywood is only interested in perpetuating negative stereotypes about hackers. But in scenes where the plot calls for a character to be working on an electronic device, it often seems like the prop department just sticks a soldering iron in the actor’s hand and calls it a day.

Of course, there are some exceptions. In the final episode of Marvel’s Hawkeye, the titular character is shown building some custom gear in a work area that looks suspiciously like somewhere actual work might get done. The set design was impressive enough that [Giovanni Bernardo] decided to pause the show and try to identify some of the tools and gadgets that litter the character’s refreshingly chaotic bench.

Now to be clear, we haven’t personally seen the latest Marvel spectacle from the House of Mouse, and it’s entirely possible that the illusion falls apart when taken as a whole. But from what we’re seeing here, it certainly looks like whoever did the set dressing for Hawkeye seems to have made an effort to recreate the hackerspace chic. We’ve got a multimeter within arm’s reach, the classic magnifying glass third arm, a Wiha screwdriver about to roll out of frame, and even some JB-Weld. If this looks eerily like what’s currently on your own bench, don’t worry, you’re not alone.

On the wider shot, we can see that the attention to detail wasn’t limited to the close-up. From the tools hanging on the pegboard to the shelves filled with rows of neatly labeled bins, we totally buy this as a functional workspace. It’s quite a bit neater than where we currently do our tinkering, but that’s more of a personal problem than anything. As we’ve seen, there are certainly people in this community who take their organization seriously.

Portrayals of science or technology in the media often leave a lot to be desired, which is why it’s so important to praise productions that put in the effort to get things right. With a little luck, maybe it will get through to the right people and raise the bar a bit. But even if it doesn’t change anything, we can at least give the folks behind the scenes some well-deserved recognition.

Build Your Own High-Temp Oven Thermometer

December 29, 2021 by Tom Nardi 9 Comments

Looking to keep an eye on the temperature inside his wood-fired pizza oven, [Giovanni Bernardo] decided to skip the commercial offerings and build his own high-temperature thermometer using a type-K thermocouple. The end result is a no-nonsense handheld unit with a surprisingly low part count that, at least in theory, can read temperatures as high as 1023.75°C. Though we hope he’ll be pulling the pizza out long before that.

Inside the 3D printed case we find just a handful of components. The 0.91″ OLED display mounted in the front panel is wired to a Digispark ATtiny85 development board, which in turn is connected to a MAX6675 breakout board. This takes the input from the thermocouple probe and converts it into a digital signal that can be read over SPI with an Arduino library from Adafruit. Rather than going through the added complication of adding a rechargeable pack, [Giovanni] is running this thermometer from a standard 9 V battery thanks to the 5 V regulator built into the Digispark.

We especially appreciate the attention to detail [Giovanni] put into his case design. Each component is nestled into a perfectly formed pocket in the bottom of the box, and he’s even gone through the trouble of using heat-set inserts for the front panel screw holes. It would have been quicker and easier to just model up a basic box and hot glue his components in place, but he took the long way around and we respect that.

This project is another example of an interesting principle we’ve observed over the years. Put simply, if somebody is going through this much trouble to check an object’s temperature, there’s a higher than average chance they intend on eating it at some point.