High-Power Laser Salvaged From Headlights

[DiodeGoneWild]’s latest video lives up to the name. He takes apart a laser headlight to recover a pretty powerful blue laser. You can see the video, below.

The headlights work with blue laser diodes that excite phosphor to produce white light. Removing the outside trappings revealed a three-pin laser diode (the case is the third pin). There’s also a substantial heatsink. Removing the diode from the assembly is difficult, but it is easy enough to leave it in the heatsink and use the existing connector.

Of course, the phosphor and a filter have to go. Some destructive work with a screwdriver and pliers broke out the optics from a diode he’d destroyed trying to remove it. Then he replaced the optics on the remaining diode with the modified housing.

With a low-current test, the diode didn’t lase but did act as a regular LED. More current did the trick, though. The laser without the optics made a line rather than a spot but still had enough power to melt some plastic and light matches. To get a parallel beam, the internal lens needs to move closer to the diode, and a drill bit allowed that to happen, which reduced the beam’s divergence quite a bit, but didn’t create the best result.

With the proliferation of cheap laser modules, it is really worth scrapping a headlight? Maybe. But it is an interesting look inside of a modern headlight, either way. We’ve peeked inside these headlights before. Maybe you can turn those old headlights into an oven.

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Linux Fu: Fusing Hackaday

Unix and, by extension, Linux, has a mantra to make everything possible look like a file. Files, of course, look like files. But also devices, network sockets, and even system information show up as things that appear to be files. There are plenty of advantages to doing that since you can use all the nice tools like grep and find to work with files. However, making your own programs expose a filesystem can be hard. Filesystem code traditionally works at the kernel module level, where mistakes can wipe out lots of things and debugging is difficult. However, there is FUSE — the file system in user space library — that allows you to write more or less ordinary code and expose anything you want as a file system. You’ve probably seen FUSE used to mount, say, remote drives via ssh or Dropbox. We’ve even looked at FUSE before, even for Windows.

What’s missing, naturally, is the Hackaday RSS feed, mountable as a normal file. And that’s what we’re building today.

Writing a FUSE filesystem isn’t that hard, but there are a lot of tedious jobs. You essentially have to provide callbacks that FUSE uses to do things when the operating system asks for them. Open a file, read a file, list a directory, etc. The problem is that for some simple projects, you don’t care about half of these things, but you still have to provide them.

Luckily, there are libraries that can make it a lot easier. I’m going to show you a simple C++ program that can mount your favorite RSS feed (assuming your favorite one is Hackaday, of course) as a file system. Granted, that’s not amazing, but it is kind of neat to be able to grep through the front page stories from the command line or view the last few articles using Dolphin. Continue reading “Linux Fu: Fusing Hackaday”

A Hombrew Retro Laptop

We feel bad when we see a retrocomputer project and think, “Hey! That’s not that old.” But, usually, when we think about it, it really is. Take the Penkesu. It looks like one of the little organizer computers that were popular — ok — a long time ago.

Inside is a Raspberry Pi Zero 2W, a 7.9 inch 400×1280 screen and a 48-key mechanical keyboard. Unsurprisingly, the case is mostly 3D printed, but it does use Gameboy Advance SP hinges.

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Printing Magnets

A research center in Spain has been working on ways to solve recent supply chain issues. One of these issues is a shortage of materials to make magnets. Their answer? Recycle ferrite residue by treating it and mixing it with ABS for 3D printing.

The mixing of ferrite with a polymer isn’t the key though, instead the trick is in the processing. The team collected strontium ferrite waste and ground it to a powder. Heating to the point of calcination (about 1000C) creates a superior material with a 350% increase in coercitivity and a 25% increase in remanence over the original waste material.

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As Fast As A Speeding Bullet

[Electronoobs] built a coil gun and the obvious question is: how fast is the projectile? To answer it, he built a chronograph suitable for timing a bullet. The principle is straightforward. A laser and a light sensor would mark the entry and exit of the projectile over a known distance. As it turns out, there are some issues to resolve.

For one thing, a laser is too narrow and might miss the projectile. The first attempt to rectify this used mirrors, but the loss was too great — we suspect he was using a second surface mirror. The final answer was to use an array of detectors and removed the laser’s collimation lens to cover a wider area.

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3D Printing Tiny Metal Parts

It may sound like a pop band, but μ-WAAM is actually a 3D printing technique for making small metal parts from the NOVA University Lisbon. Of course, WAAM stands for wire arc additive manufacturing, a well-known technique for 3D printing in metal. The difference? The new technique uses 250 μm wire stock instead of the 1mm or thicker wires used in conventional WAAM.

The thinner feed wire allows μ-WAAM to create fine details like thin walls that would be difficult to replicate with traditional methods. Typically, for fine structures, printers use fused metal powder. This is good for fine details, but typically slower and has higher waste than wire-based systems.

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Predicting The Future: How’s That Working Out?

With 2022 off to a good start, it is about time to let go of all those New Year’s resolutions that didn’t quite work out. The scale’s needle didn’t reverse, our nails are still bitten, and we are still binge-watching Breaking Bad instead of reading the classics. But, of course, there’s always the future where we just know we’re going to stick to our resolutions. Besides, the future will be replete with fat-eating nanobots, 3D printed nails every morning, and a pill you can take that will make you remember reading Ulysses.

Predicting the future is fraught with peril, which is why launching a new company or product is so risky. However, there have been a few prognosticators that have made some impressive forecasts. For example, in 1922 popular (if not critically acclaimed) author W. L. George wrote a piece for The New York Herald titled “What the World Will be Like In a Hundred Years.” Since May will see that piece’s 100th anniversary, let’s see how he did.

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