Laser Triangulation Makes 3D Printer Pressure Advance Tuning Easier

May 6, 2023 by Dan Maloney 8 Comments

On its face, 3D printing is pretty simple — it’s basically just something to melt plastic while being accurately positioned in three dimensions. But the devil is in the details, and there seems to be an endless number of parameters and considerations that stand between the simplicity of the concept and the reality of getting good-quality prints.

One such parameter that had escaped our attention is “pressure advance,” at least until we ran into [Mike Abbott]’s work on automating pressure advance calibration on the fly. His explanation boils down to this: the pressure in a 3D printer extruder takes time to both build up and release, which results in printing artifacts when the print head slows down and speeds up, such as when the print head needs to make a sharp corner. Pressure advance aims to reduce these artifacts by adjusting filament feed speed before the print head changes speed.

The correct degree of pressure advance is typically determined empirically, but [Mike]’s system, which he calls Rubedo, can do it automatically. Rubedo uses a laser line generator and an extruder-mounted camera (a little like this one) to perform laser triangulation. Rubedo scans across a test print with a bunch of lines printed using different pressure advance values, using OpenCV to look for bulges and thinning caused when the printer changed speed during printing.

The video below gives a lot of detail on Rubedo’s design, some shots of it in action, and a lot of data on how it performs. Kudos to [Mike] for the careful analysis and the great explanation of the problem, and what looks to be a quite workable solution.

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A miniature 486 desktop PC running Lemmings

Tiny 3D Printed Gaming PC Contains Real Retro Hardware

May 6, 2023 by Robin Kearey 13 Comments

Emulators are easy and convenient, but for some retrocomputing enthusiasts nothing comes close to running classic software on actual era-appropriate hardware. This can become a problem, though, for those into vintage PC gaming: old PCs and their monitors are notoriously large and heavy, meaning that even a modest collection will quickly fill up a decent family home. There is a solution however, as [The Eric Experiment] demonstrates in his latest video. He designed and built a 3D-printed mini PC that runs on an actual 486 processor.

An ordinary desktop motherboard would have required a rather large case to begin with, so [Eric] started his project by buying an old industrial PC board. Such a device has the processor and all main motherboard components sitting on an ISA card, which then connects to other ISA cards through a backplane. This way, a complete system with expansion cards can be made way more compact than even the sleekest desktop PCs of the time. An SD-card-to-IDE converter makes for an extremely slim hard drive replacement, while a Gotek floppy emulator allows the system to boot as if there’s actually a floppy drive present.

A small 486 tower case being assembled — Even the side panels slide in exactly like they do on real PC cases.

All of this is pretty neat to begin with, but by far the most impressive parts of the Tiny 486 project are the enclosures that [Eric] designed for the PC and its accompanying monitor. Both were modelled off real-world examples and are accurate down to the smallest details: the tilting stand that clips onto the base of the monitor for instance, or the moving latch on the faux 5.25″ floppy drive. That latch operates a cleverly hidden door that reveals the USB connector for the floppy emulator. The compulsory seven-segment LED display on the mini tower’s front panel now finally serves a useful purpose – indicating which floppy image is currently active.

Sporting an Intel 486-DX4 100 MHz processor, 32 MB of RAM, a Tseng ET4000 video card and an ESS Audiodrive for sound, the tiny 486 can run DOS or Windows 95, although performance in the latter is a bit limited due to the lack of a local-bus video card. It’s perfectly fine for most DOS games though, and a lot more practical than a full-sized desktop PC.

There are several ways to make a tiny game PC, like using PC/104 standard boards or repurposing old network equipment. The crucial part needed to turn it into a gaming machine is a proper sound card, which you can even build from scratch if needed. Thanks for the tip, [Nathan]!

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PC Classics, Right In Your Browser With EmuOS

May 6, 2023 by Donald Papp 12 Comments

[Emupedia]’s work to preserve computer history by way of making classic and abandoned games and software as accessible as possible is being done in a handy way: right in your browser with EmuOS.

A few moments of BIOS startup kicks off EmuOS right in a browser window.

Doing things this way has powerful “Just Works” energy. Visit that link in a modern browser and in no time at all you’ll be looking at a Windows 95 (or Windows 98, or Windows ME) desktop, filled with a ton of shortcuts to pre-installed and ready-to-run classic software. Heck, you can even keep it simple and be playing the original Microsoft Solitaire in no time flat. There is also a whole ton of DOS software waiting to be fired up, just double-click the DOSBox icon, and browse a huge list. The project is still in development, so not everything works, but the stuff that does is awfully slick.

Here’s some additional background that goes into more detail about the project and its capabilities, but if you’d prefer to just click around to explore, here’s the main link again (and here’s a list of mirrors.)

If OS emulation is your thing, don’t miss emulating the IBM PC on an ESP32 microcontroller. And if you’re more into lesser-known vintage operating systems, how about re-inventing PalmOS to run on x86 architecture?

The New Hotness

May 6, 2023 by Elliot Williams 35 Comments

If there’s one good thing to be said about the chip shortage of 2020-2023 (and counting!) it’s that a number of us were forced out of our ruts, and pushed to explore parts that we never would have otherwise. Or maybe it’s just me.

Back in the old times, I used to be a die-hard Atmel AVR fan for small projects, and an STM32 fan for anything larger. And I’ll freely admit, I got stuck in my ways. The incredible abundance of dev boards in the $2 range also helped keep me lazy. I had my thing, and I was fine sticking with it, admittedly due to the low price of those little blue pills.

And then came the drought, and like everyone else, my stockpile of microcontrollers started to dwindle. Replacements at $9 just weren’t an option, so I started looking around. And it’s with no small bit of shame that I’ll admit that I hadn’t been keeping up with the changes as much as I should have. Nowadays, it’s all ESP32s and RP2040s over here, and granted there’s a bit of a price bump, but the performance is there in abundance. But I can’t help feeling like I’m a few years back of the cutting edge.

So when I see work like what [CNLohr] and [Bitluni] are doing with the ultra-cheap CH32V003 microcontrollers, it makes me think that I need to start filling in gaps in my comfortable working-set of chips again. But how the heck am I supposed to keep up? And how do you? It took a global pandemic and silicon drought to force me out of my comfort zone last time. Can the simple allure of dirt-cheap chips get me out? We’ll see!

How To Model A Twisted Part In FreeCAD

May 6, 2023 by Donald Papp 84 Comments

Quick references are handy, but sometimes it’s nice to have a process demonstrated from beginning to end. In that spirit, [Darren Stone] created a video demonstrating how to model a twisted part in FreeCAD, showing the entire workflow of creating the part as a blend of surfaces and curves that get turned into a solid.

FreeCAD is organized using the concept of multiple “workbenches” which are each optimized for different tools and operations, and [Darren] walks through doing the same jobs in a few different ways.

This twisted bracket is a simple part that is nevertheless nontrivial from a CAD perspective, and that makes it a good candidate for showing off the different workbenches and tools.

The video below is also pretty good overall demonstration of what designing a part from a mechanical drawing looks like when done in FreeCAD. As for mechanical drawings themselves, we’ve seen FreeCAD can be used to make those, too.

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Inside A Pair Of Smart Sunglasses

May 6, 2023 by Bryan Cockfield 14 Comments

If you’re willing to spend $200 USD on nothing more than 100 grams of plastic, there are a few trendy sunglasses brands that are ready to take your money before you have time to think twice. Sure, you can get a pair of sunglasses for an order of magnitude less money that do the exact same job, but the real value is in the brand stamped into the plastic and not necessarily the sunglasses themselves. Not so with this pair of Ray-Bans, though. Unlike most of their offerings, these contain a little bit more than a few bits of stylish plastic and [Becky Stern] is here to show us what’s hidden inside.

At first glance, the glasses don’t seem to be anything other than a normal pair of sunglasses, if a bit bulky But on closer inspection they hide a pair of cameras and a few other bits of electronics similar to the Google Glass, but much more subtle. The teardown demonstrates that these are not intended to be user-repairable devices, and might not be repairable at all, as even removing the hinges broke the flexible PCBs behind them. A rotary tool was needed to remove the circuit boards from the ear pieces, and a bench vice to remove the camera modules from the front frame. We can presume these glasses will not be put back together after this process.

Hidden away inside is a pair of cameras, a Snapdragon quad-core processor, capacitive touch sensors, an amplifier for a set of speakers. Mostly this is to support the recording of video and playback of audio, and not any sort of augmented reality system like Google Glass attempted to create. There are some concerning ties with Facebook associated with this product as well which will be a red flag for plenty of us around here, but besides the privacy issues, lack of repairability, and lack of features, we’d describe it as marginally less useful as an entry-level smartwatch. Of course, Google Glass had its own set of privacy-related issues too, which we saw some clever projects solve in unique ways.

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A Dedicated GPU For Your Favorite SBC

May 5, 2023 by Bryan Cockfield 35 Comments

The Raspberry Pi is famous for its low cost, versatile and open Linux environment, and plentiful I/O, making it a perfect device not only for its originally-intended educational purposes but for basically every hobbyist from gardeners to roboticists to amateur radio operators. Most builds tend to make use of the GPIO pins which allow easy connections to various peripherals and sensors, but the Pi also supports PCI devices which means that, in theory, it could use a GPU in much the same way that a modern computer would. After plenty of testing and development, [Jeff Geerling] brings us this custom graphics card interface for the Raspberry Pi.

The testing for all of these graphics cards has been done with a Pi Compute Module 4 and the end result is an interface device which looks much like a graphics card itself. It splits the PCI bus out onto a more familiar x16 slot connector and adds physical connections for power, USB, and Ethernet. When plugged into the carrier board, the Compute Module can be attached to any of a number of graphics cards, including the latest and highest-end of Nvidia and AMD offerings.

Perhaps unsurprisingly, though, the 4090 and 7900 cards don’t work with the Raspberry Pi. This is partially due to the 32-bit limitations of the Pi and other memory mapping issues, but even after attempting some workarounds Nvidia’s cards aren’t open-source enough to test properly (although the card is recognized by the Pi) and AMD’s drivers crash the system even after compiling a custom kernel. [Jeff] did find an Nvidia card that worked, although it requires using the USB interface and second-hand cards are selling for around $3000 USD. For a more economical choice there are some other graphics cards that he was eventually able to get working, albeit not with perfect performance, including some of the ones we’ve seen him test already.

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