Building An Affordable Press For Heat Set Inserts

September 9, 2020 by 11 Comments

If you’re building mechanical assemblies with 3D printed parts, you’ll quickly realize that driving machine screws into thermoplastic isn’t exactly an ideal solution. It can work in a pinch, but you can easily strip the threads if you crank down too hard. The plastic holes can also get worn down from repeated use, which is a problem if you’re working on something that needs to be taken apart and reassembled frequently. In those situations, using brass heat set inserts gives the fasteners something stronger to bite into.

You can install these inserts by hand, but if you plan on doing a lot of them, a dedicated press station like the one [Chris Chimienti] recently put together will save you a lot of aggravation in the long run. In the video after the break he walks viewers through the design and use of the device, which itself relies on a number of 3D printed parts using the very same inserts it’s designed to install.

The spring-loaded arm can slide up and down the extrusion to adjust for height.

To build this tool you’ll need a piece of aluminum extrusion, some smooth rod, a couple springs, and an assortment of fasteners. Nothing that wouldn’t likely be in the parts bin of anyone who’s been tinkering with 3D printers for awhile, though even if you had to buy everything, the Bill of Materials will hardly break the bank. For the base you can use a piece of scrap wood, though [Chris] has opted to make it a storage compartment where he can store the inserts themselves. We really like this approach, but obviously you’ll need to have access to woodworking tools in that case.

Clearly shopping on the top shelf, [Chris] purchased a kit that actually came with a Weller soldering iron and the appropriate tips for the various sized inserts. If you’re like us and just buy the inserts that come in a plastic baggie, you may need to adapt the arm to fit your iron of choice. That said, the idea of having a dedicated iron that you can leave mounted in the press makes a lot of sense to us if you can swing it.

[Joshua Vasquez] wrote up a phenomenal guide to getting started with heat set inserts last year that’s an absolute must-read for anyone interested in the concept. Whether you build a dedicated press or just push them in freehand, his tips and tricks will help insure you get the best result possible.

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Google Turns Android Up To 11 With Latest Update

September 9, 2020 by 32 Comments

Just going by the numbers, it’s a pretty safe bet that most Hackaday readers own an Android device. Even if Google’s mobile operating system isn’t running on your primary smartphone, there’s a good chance it’s on your tablet, e-reader, smart TV, car radio, or maybe even your fridge. Android is everywhere, and while the development of this Linux-based OS has been rocky at times, the general consensus is that it seems to have been moving in the right direction over the last few years. Assuming your devices actually get the latest and greatest update, anyway.

So it’s not much of a surprise that Android 11, which was officially released yesterday, isn’t a huge update. There’s no fundamental changes in the core OS, because frankly, there’s really not a whole lot that really needs changing. Android has become mature enough that from here on out we’re likely to just see bug fixes and little quality of life improvements. Eventually Google will upset the apple cart (no pun intended) with a completely new mobile OS, but we’re not there yet.

Of course, that’s not to say there aren’t some interesting changes in Android 11. Or more specifically, changes that may actually be of interest to the average Hackaday reader. Let’s take a look at a handful of changes and tweaks worth noting for the more technical crowd.

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Tesla Coil Electric Bike Is Wireless

September 9, 2020 by 28 Comments

Electric bikes, and really all electric vehicles, have one major downside: the weight and cost of batteries. Even with lithium, battery packs for ebikes can easily weigh more than the bike itself and cost almost as much. But having to deal with this shortcoming could be a thing of the past thanks to [LightningOnDemand]’s recent creation. Of course, this would rely on a vast infrastructure of Tesla coils since that’s how this bike receives the power it needs to run its electric motor.

The Tesla coil used for the demonstration is no slouch, either. It’s part of the Nevada Lightning Laboratory and can pack a serious punch (PDF warning). To receive the electrical energy from the coil, the bike (actually a tricycle) uses a metal “umbrella” of sorts which then sends the energy to the electric motor. The bike drags a chain behind itself in order to have a ground point for the electricity to complete its circuit. There is limited range, though, and the Tesla coil will start ionizing paths to the ground if the bike travels too far away.

While we can’t realistically expect Tesla’s idea of worldwide, free, wireless electricity to power our bicycles anytime soon, it is interesting to see his work proven out, even if its on a small scale like this. Of course, it doesn’t take a research laboratory to start working with Tesla coils. This one is built out of common household parts and still gets the voltages required to create the signature effects of a Tesla coil.

Thanks to [Adam] for the tip!

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Paper Keyboard Is Self-Powered

September 9, 2020 by 12 Comments

Building a keyboard isn’t a big project these days. Controller chips and boards are readily available, switches are easy to find, and a 3D printer can do a lot of what used to be the hard parts. But engineers at Purdue have printed a self-powered Bluetooth keyboard on an ordinary sheet of paper. You can see videos of the keyboards at work below.

The keyboards work by coating paper with a highly fluorinated coating that repels water, oil, and dust. Special inks print triboelectric circuits so that pressing your finger on a particular part of the paper generates electricity. We were skeptical that the Bluetooth part is self-powered, although maybe it is possible if you have some very low-power electronics or you manage the power generated very carefully.

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LEGO Delivers Corvette Experience On A Budget

September 8, 2020 by 5 Comments

Many dream of tooling around in a high performance sports car, but the cost of owning, maintaining, and insuring one of them make it a difficult proposition. While this LEGO version of the Corvette ZR1 might not be exactly like the real thing, it’s 4-speed manual and electronic gauge cluster can give you a taste of the supercar lifestyle without having to taken out a second mortgage.

Working through the gears.

Built by [HyperBlue], this desktop speedster has more going on under the hood (or more accurately, the roof) than you might expect. While it looks pretty unassuming from the outside, once the top is lifted, you can see all the additional components that have been packed in to motorize it. The functional gearbox takes up almost the entire interior of the car, but it’s not like you were going to be able to fit in there anyway.

But the motorized car is really only half of the project. [HyperBlue] has built a chassis dynamometer for his plastic ride that not only allows you to “start” the engine with realistic sights and sounds (recorded from an actual GM LT1 V8 engine), but put the mini ‘Vette through its paces. With a virtual dashboard powered by the Raspberry Pi, you can see various stats about the vehicle such as throttle position, RPM, and calculated scale speed; providing a real-world demonstration of how the transmission operates.

While a LEGO sports car might not be quite as exciting as getting yourself a real project car, there’s something to be said for being able to rebuild your transmission without getting your hands dirty.

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Tutorial For Setting Up Raspberry Pi For Ham Radio Use

September 8, 2020 by 9 Comments

There was a time when a ham radio set up sported many dials and switches and probably quite a few boxes as well. Computers have changed all that. Some transceivers now have just a few buttons or are even totally computer-controlled. Where a ham, at one time, might have a TeleType machine, a slow-scan TV monitor, and a fax printer for receiving satellite images, now that can all be on a single computer which can even be a Raspberry Pi. [F4GOH] has a post that takes you from the fundamentals to installing everything from an SDR to many common ham programs for digital modes, APRS, SSTV, and more. You can download the seven-part tutorial as separate PDF files, too.

Even if you aren’t a ham, you might find some of the software interesting. OpenWebRX lets you listen to your software defined radio on the road. You can use other software to pick up weather satellite data.

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Measure 1024 Times, Cut Once

September 8, 2020 by 25 Comments

Typically, someone’s first venture into coding doesn’t get a lot of attention. Then again, most people don’t program a CNC table saw right out of the gate. [Jeremy Fielding] wasn’t enticed with “Blink” or “Hello, world,” and took the path less traveled. He tackled I/O, UX, and motion in a single project, which we would equate to climbing K2 as a way to get into hiking. The Python code was over 500 lines, so we feel comfortable calling him an over-achiever.

The project started after he replaced the fence on his saw and wondered if he could automate it, and that was his jumping-on point, but he didn’t stop there. He automated the blade height and angle with stepper motors, so the only feedback is limit switches to keep it from running into itself. The brains are a Raspberry Pi that uses the GPIO for everything. There is a manual mode so he can use the hand cranks to make adjustments like an ordinary saw, but he loses tracking there. His engineering background shines through in his spartan touchscreen application and robust 3D model. The built-in calculator is a nice touch, and pulling the calculations directly to a motion axis field is clever.

We’ve covered [Jeremy]’s DIY dynamometer and look forward to whatever he builds next. Until then, check out a light-duty approach to CNC that cuts foam in two-and-a-half dimensions.

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