Rescuing A Rescue Device With A DIY Battery Pack

September 3, 2026 by Tom Nardi No comments

If you find yourself lost in the woods or adrift in the ocean, a GPS-enabled Personal Locator Beacon (PLB) is certainly a handy thing to have as it will pinpoint your location for rescuers. The one [Steve Jernigan] has is relatively affordable considering it might save your life one day, but it turns out that replacement batteries for the unit are extremely expensive and hard to come by because the manufacturer would rather you send the unit back to them for refurbishment. So naturally, he took it apart and figured out how to do it himself.

His DIY battery pack consists of a small custom PCB and pair of off-the-shelf 6 volt lithium manganese dioxide cells in a 3D printed enclosure that slots into the rear of the McMurdo PLB. In assembly video below, [Steve] shows how the pack goes together and demonstrates the use of a two-part potting compound in an effort to keep the elements at bay.

Before anyone says it — putting a homemade battery pack into a device which one day might be the only thing standing between you and death is probably not a great idea. [Steve] mentions in the description of this project that this is meant for backup purposes, and that you should really spring for a legitimate battery if there’s a chance you might actually need to be rescued at some point.

If you’re interested in battery pack hacking that doesn’t potentially risk life and limb, fixing the one that came with your cordless drill might be a better project to start with. Continue reading “Rescuing A Rescue Device With A DIY Battery Pack” →

Miniaturized, Working Replica Of Vintage Leslie Speaker

September 3, 2026 by Bryan Cockfield 3 Comments

Few pieces of vintage audio gear from the turn of the century (the previous one) inspire the kind of devotion that a Leslie speaker does. Sure, there are plenty of pieces that are rarer or more valuable, but the Leslie speaker has such a big following because of its uniqueness of physically moving sound around a room. Two rotating devices in the speaker physically direct the sound around the cabinet with musician-controlled speed, and this sound remains extremely difficult to reproduce faithfully without the moving components. But originals are enormous and meant for organs, so [Eric] built a 40% replica with a few modern touches for his guitar.

The build starts with a CAD model, where [Eric] works towards making the most accurate enclosure for his speaker as possible. The CAD model heads out to a CNC machine which can care most of the details into the wood, and he eventually is able to finish it, although it took a few tries with stains and paintbrushes of various types. For the speakers themselves, he’s using modern versions including modern brushless motors to drive the rotating elements. Like the original speaker, the high range of sound is sent through a rotating set of horns, of which one is only a counterweight, and the low range is directed out of the bottom of the cabinet through a large rotating drum. Both rotating elements here are 3D printed, and with everything put together and wired up [Eric] has a much more portable, faithful recreation of the original Leslie speaker.

There are some upgrades in the wiring too, which makes it work better with a guitar rather than for an organ. It’s also much lighter, and was a hit when he took it to let a few other guitarists to play as well. It’s not the first time we’ve seen the Leslie’s movement recreated for guitar, but it is the most alike to the classic 1930s-era speaker we’ve seen so far.

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Switch Mod Fixes Fiddly Car Door Projector

September 2, 2026 by Tom Nardi 16 Comments

While the Citroën logo they project onto the pavement looks great, [OrangeTungsten] wasn’t thrilled with how their door-mounted projectors actually functioned. The mechanism for detecting when they should kick on was a bit too clever for its own good, and needed to be simplified a bit. Luckily for us, the process was meticulously documented for anyone else who might find themselves in a similar situation.

Originally, the projector detected when it should turn on by sensing the presence of a tiny magnet using a Hall effect sensor. There are certainly some advantages to this approach, but in practice, [OrangeTungsten] says the retrofitted magnet would keep falling off and leaving the projector inoperative. The fix was simple enough: figure out how the circuit worked, pull out the Hall effect sensor, and replace it with a simple button that would physically make contact with the door frame.

It’s not a terribly complex fix, but it’s a clever solution and well documented, and that goes pretty far around these parts. We were also interested in this one because an examination of the electronics inside the projector uncovered a 8-pin microcontroller — the sole purpose of which would appear to be polling the Hall effect sensor and using its status to throw a transistor which in turn powers the LED.

It’s hard to believe that whoever designed this gadget couldn’t figure out how to turn an LED on and off without a MCU, but we’re living in strange times. We assume there’s some kind of justification for this, such as some flashing or fading effects, but [OrangeTungsten] never mentions the things doing anything more complex than simply turning on and off.

Whatever the rationale was behind the original design of these projectors, the important thing is that the application of some hardware from the parts bin got them up and working again, which is something we never get tired of seeing.

Has FDM 3D Printing Hit Its Peak?

September 2, 2026 by Jenny List 18 Comments

Over the time Hackaday has been in existence, the art of 3D printing has evolved from a relatively crude hit-and-miss affair to something approaching what we all imagined back then. You can’t yet walk up to a Star Trek replicator and ask for a part, but a modern state of the art consumer or prosumer grade printer will deliver consistent high-resolution parts, and in a surprisingly short time. [The Next Layer] asks whether consumer FDM printers have now reached the point at which they’re about as good as they’re going to get, and whether other technologies hold the future.

It’s a fair point to make that the resolution of a consumer FDM printer may be close to its mechanical limit. Techniques such as input shaping and the adoption of better CoreXY mechanisms mean that prints which once might have relied on SLA can be done in FDM. Healthy competition in the marketplace has delivered high quality colour printing, with tool-changing printers being no longer solely the preserve of the professional. He uses the example of a mobile phone to make the point that new machines have less of a wow factor to deliver, as increments have become less grand.

It’s a persuasive argument, and looking at the printers around us we can see it in action. The difference in ability between a 2020-ish and a 2026 FDM printer are far smaller than those between the same time periods in the last decade. Compare a MakerBot Cupcake and an Ultimaker II, or the Ultimaker and a Prusa Mini, and each is light years ahead of the last. But the best the Mini can do is surprisingly not as far behind as you’d expect to that of their latest, or of the equivalent from Bambu Labs.

Does this means that nothing new is coming in 3D printing? Of course not. UV printing is coming through and will deliver incredible results, as will SLS printing. It’s interesting he devotes little time to SLA printing, perhaps because it’s not as easy a process as FDM. He makes the point that we’ve never had it so good, as the high-end FDM features will appear in modestly priced machines, and we have those other technologies to look forward to.

It’s an interesting discussion, and you can see it below the break.

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Doubling Thermal Printer Resolution By Wiggling

September 2, 2026 by Maya Posch 6 Comments

Insides of the Sears 12 calculator. (Credit: Danalog, YouTube)

Thermal printers are still extremely common today, using small heating elements in combination with temperature-sensitive paper to create a dot matrix-like effect without messing with ink ribbons and complex mechanisms. Of course, even with just a line of elements you still needed one of these per pixel, which at least in the 1970s when the Sears 12 calculator was released added significantly to the cost. The solution here was to wiggle the elements, doubling the resolution of the print head, as detailed in this video by [Danalog].

Using a contemporary Texas Instruments TI-5015 calculator as comparison with its non-wiggling print head, it’s easy to see the advantages here. In an era where electronic calculators didn’t have displays but a thermal printer, this print quality was the selling point, yet adding more thermal elements added to the price tag of the final device and more complexity to the design in terms of driving circuitry.

In this regard adding a way to make the print head move side-to-side at a set rate and tying this fact into the printing would save about half of that circuitry. Inside the Sears 12 is a fairly standard Mitsubishi M58671 calculator IC, but also the whole printer mechanism. When operating, as demonstrated in the video with the cover removed, you can see the whole print head moving rapidly.

With this mechanism this much cheaper Sears 12 definitely gives the TI-5015 a run for its money, even if as noted by [Danalog] the timing would go off a bit after a longer session, resulting slightly wavy printing. Presumably with the massive cost savings of buying a Sears calculator over a TI one, this was deemed an acceptable trade-off.

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Harvesting Namib Desert Fog With High Voltage

September 2, 2026 by Maya Posch 11 Comments

As fun as mucking about with simulated environments in a laboratory is, at some point you have to do those field tests to demonstrate that your prototype actually works in the real world, under real conditions. This is what the [Plasma Channel] recently did for their fog harvesting system by setting it up in the Namib desert.

We previously covered the atmospheric water harvesting attempts, using electrostatic precipitation to draw the moisture in the air onto the collectors where it can then be harvested. This is rather different from existing approaches with e.g. fine meshes and hoping that enough water molecules bump into your mesh, so theoretically it should be much more efficient. In the lab it worked well, but reality always has the last word.

The Namib desert is at the top of the world’s most arid regions, competing with the Atacama desert. What it does have going for it is regular fog rolling in that lasts until sunrise, providing a good target for water harvesting. Interestingly, this field test was performed together with the University of Namibia.

Of course, moving the prototype in check-in luggage for the flight to Namibia took some redesigning and testing. Fortunately everything, including the solar panel, arrived intact, allowing trials to commence. This initially took place at the campus of the University of Namibia, joining a number of other atmospheric water harvesting projects that had been previously installed there.

Unfortunately the fog proved to be rather elusive, leading to a few fruitless attempts. It also proved that the salt in the air from the ocean spray, even a few kilometers inland, was highly corrosive, especially to high-voltage electronics. Although the system basically worked, happily harvesting water under the right conditions, it does need some redesign before it’ll be tested next in the Atacama desert.

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FLOSS Weekly Episode 880: The Two Wolves

September 2, 2026 by Jonathan Bennett No comments

This week Jonathan chats with Benjamin Samuels of Trail of Bits! The conversation focuses on Patch the Planet, a new initiative to help Open Source projects deal with the fallout from AI coding and vulnerability research. What’s the unexpected dichotomy driving the polarized response to LLMs? And what does the future look like for Open Source in the age of AI? Watch to find out!

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