3D Printing Latex Is Now Possible

July 27, 2020 by Zoe Skyforest 14 Comments

For those getting started with 3D printers, thermoplastics such as ABS and PLA are the norm. For those looking to produce parts with some give, materials like Ninjaflex are most commonly chosen, using thermoplastic polyeurethane. Until recently, it hasn’t been possible to 3D print latex rubber. However, a team at Virginia Tech have managed the feat through the combination of advanced printer hardware and some serious chemistry.

Sample cubes printed with the new process. Note the clarity of the sample at the top right.

The work was primarily a collaboration between [Phil Scott] and [Viswanath Meenakshisundaram]. After initial experiments to formulate a custom liquid latex failed, [Scott] looked to modify a commercially available product to suit the project. Liquid latexes are difficult to work with, with even slight alterations to the formula leading the solution to become unstable. Through the use of a molecular scaffold, it became possible to modify the liquid latex to become photocurable, and thus 3D printable using UV exposure techniques.

The printer side of things took plenty of work, too. After creating a high-resolution UV printer, [Meenakshisundaram] had to contend with the liquid latex resin scattering light, causing parts to be misshapen. To solve this, a camera was added to the system, which visualises the exposure process and self-corrects the exposure patterns to account for the scattering.

It’s an incredibly advanced project that has produced latex rubber parts with advanced geometries and impressive mechanical properties. We suspect this technology could be developed quickly in the coming years to produce custom rubber parts with significant strength. In the meantime, replicating flexible parts is still possible with available filaments on the market.

[via phys.org]

A Low-Cost Current Probe For IoT Applications

July 27, 2020 by Zoe Skyforest 13 Comments

When it comes to the Internet of Things, many devices run off batteries, solar power, or other limited sources of electricity. This means that low power consumption is key to success. However, often these circuits draw relatively small currents that are difficult to measure, with plenty of transient current draw from their RF circuits. To effectively measure these low current draws, [Refik Hadzialic] built a cheap but accurate current probe.

The probe consists of a low value resistor of just 0.1 Ω, acting as a current shunt in series with the desired load. By measuring the voltage drop across this known resistor, it’s possible to calculate the current draw of the circuit.

However, the voltage drop is incredibly small for low current draws, so some amplification is needed. [Refik] does a great job of explaining his selection process, going deep into the maths involved to get the gain and part choice just right. The INA128P instrumentation amplifier from Texas Instruments was chosen, thanks to its good Common Mode Rejection Ratio (CMRR) and gain bandwidth.

The final circuit performs well, competing admirably with the popular uCurrent Gold measurement tool. While less feature-packed, [Refik]’s circuit appears to perform better in the noise stakes, likely due to the great CMRR rating of the TI part. It’s a great example of how the DIY approach can net solid results over and above simply buying something off the shelf.

Current sensing is a key skill to have in your toolbox, and can even help solve laundry disputes. Video after the break.

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MP3 Is 25 Years Old!

July 27, 2020 by Zoe Skyforest 127 Comments

In the streaming era, music is accessed from a variety of online services, ephemeral in nature and never living on board the device. However, the online audio revolution really kicked off with the development of one very special format. The subject of bitter raps and groundbreaking lawsuits, this development from Germany transformed the music industry as we know it. Twenty-five years on from the date the famous “.mp3” filename was chosen, we take a look back at how it came to be, and why it took over the world.

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3D Printed Speaker Uses DSP For Ultimate Performance

July 25, 2020 by Zoe Skyforest 17 Comments

Speaker design used to be as much about woodwork as it was about advanced acoustic mathematics. In recent decades, technologies such as digital signal processing and 3D printing have changed the game significantly. Leaning heavily on these techniques, [ssashton] developed a design called Mr. Speaker.

The speaker contains a 3″ woofer for good bass response, and twin tweeters to deliver stereo audio. Using WinISD to help do the requisite calculations on porting and volume, [ssashton] designed a swooping 3D printed enclosure with a striking design. Sound comes into the unit through an off-the-shelf Bluetooth module, before being passed to an ADAU1401 digital signal processing unit. From there, it’s passed to a mono amp to drive the woofer and a stereo one for the tweeters.

To get the flattest frequency response possible and maintain linear phase, it’s all about DSP in this case. RePhase software was used to design a DSP filter to achieve these goals, helping the speaker to produce the desired output. The ADAU1401 DSP was then programmed using Sigma Studio, which also allows the designer to do things such as split outputs for seperate woofer and tweeter drives.

[ssashton] does a great job of explaining both DSP principles and old-school speaker design tricks, from phase plugs to reflections. The use of 3D printed parts to rapidly iterate the design is impressive, too. We’d love to see the final enclsoure get an acetone smoothing treatment to really take it over the edge.

If you’re into serious speaker design and want more, be sure to check out this advanced transmission line design. For those of you with your own builds with some nifty tricks, drop us a note on the tipline.

Simple Plasma Cutter Collision Detection System

July 25, 2020 by Zoe Skyforest 7 Comments

Machine tools often have powerful drive motors, allowing them to work quickly and accurately to get the job done fast. However, this can cause major damage if the tool head collides with an unexpected object. To protect against such occurances, [Xnaron] developed a simple system to shut down his plasma cutter in the event of a crash.

The system consists of a 3D printed collar that fits around the plasma cutting torch. The collar has two mating parts, which are held together with three magnets and three ball bearings to act as a key, maintaining the correct orientation. Three limit switches are then fitted, held closed by the two mating halves. When the torch collides with an object, this causes the magnetic coupling to seperate, triggering one or more of the limit switches, and shutting down the machine safely.

Video of an unplanned collision shows the device working well. It’s a neat solution that could probably be adapted to other types of machine tool that don’t experience high lateral forces. Of course, if you don’t yet have a plasma cutter, you can always make your own. Video after the break.

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Wobble Disk Coffee Roaster Gets The Beans Just Right

July 23, 2020 by Zoe Skyforest 16 Comments

Coffee roasting is an art or a science, depending on who you talk to. Both camps will however agree that attention to detail is key. Many diehard beanheads, as they’re known, will go so far as to create their own roasting hardware to get the job done just right. [Larry Cotton] is one such builder, who has created an elegant roaster to get his brew just right.

The build is based around a wobble disk design. This consists of a round plate fixed at a 45-degree angle to a rotating shaft. As the shaft spins, the disk gently sweeps and agitates the roast, allowing the batch to heat up evenly without burning the beans. It’s a two-part design, with heat gun parts in the base to generate the hot air for the roasting process. The bean basket sits on top, held in place by magnets that also act as a conduit for the wobble disk motor’s power supply.

It’s a tidy build, which allows for accurate roasting and easy dumping of the beans once finished. If you’re a serious beanhead yourself with a few hacks up your sleeve, be sure to let us know! Video after the break.

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384 Neon Bulbs Become Attractive Display

July 23, 2020 by Zoe Skyforest 11 Comments

Neon lights have inspired much prose over the years, with their attractive light output receiving glowing adulation. [Pierre Muth] is a big fan, and decided to spend lockdown creating something suitably pretty for his desk.

An 8×8 segment of the total panel. The display draws 40W at 5V with all pixels on at the same time.

The project consists of an 8×48 matrix display constructed out of INS-1 (ИНC-1) tubes. These tiny neon tubes are 6.5 mm in diameter, showing a bright orange dot of light when powered up. Requiring just 100 V and 0.5 mA to light, they’re a touch easier to drive than the famous Nixie.

[Pierre] decided to go all out, wishing to replicate the capabilities of smart LEDs like the WS2812. These contain a microcontroller built in to each LED, so [Pierre] would have to do the same. Each of the 384 neon tubes got its own bespoke PCB, containing a PIC16F15313 microcontroller, step up voltage circuitry, and a 6-pin connector. (Whoah!) When each bulb was soldered to its PCB, they were then plugged into a backplane. An ESP32 was then employed to drive the display as a whole.

Creating a display in this fashion takes a huge amount of work, with most of it being soldering the 384 individual bulb PCBs containing 11 components each. We have a lot of respect for [Pierre]’s work ethic to get this done during lockdown, and the final result is a gloriously retro neon matrix display. We’ve featured other neon matrixes recently, too. Video after the break. Continue reading “384 Neon Bulbs Become Attractive Display” →