Compound Press Bends, Punches And Cuts Using 3D Printed Plastic

June 11, 2025 by Tyler August 8 Comments

It’s not quite “bend, fold or mutilate” but this project comes close– it actually manufactures a spring clip for [Super Valid Designs] PETAL light system. In the video (embedded below) you’ll see why this tool was needed: by-hand manufacturing worked for the prototype, but really would not scale.

Two examples of the spring in question, embedded in the 3D printed light socket. There’s another pair you can’t see.

The lights themselves might be worthy of a post, being a modular, open source DMX stage lighting rig. Today though we’re looking at how they are manufactured– specifically how one part is manufactured. With these PETAL lights, the lights slot into a base station, which obviously requires a connection of some sort. [Super Valid Designs] opted for a spring connector, which is super valid.

It’s also a pain to work by hand: spring steel needed to be cut to length, hole punched, and bent into the specific shape required. The hand-made springs always needed adjustment after assembly, too, which is no good when people are giving you money for objects. Even when using a tent-pole spring that comes halfway to meeting their requirements, [Super Valid Designs] was not happy with the workflow. Continue reading “Compound Press Bends, Punches And Cuts Using 3D Printed Plastic” →

Network Infrastructure And Demon-Slaying: Virtualization Expands What A Desktop Can Do

June 11, 2025 by Bryan Cockfield 21 Comments

The original DOOM is famously portable — any computer made within at least the last two decades, including those in printers, heart monitors, passenger vehicles, and routers is almost guaranteed to have a port of the iconic 1993 shooter. The more modern iterations in the series are a little trickier to port, though. Multi-core processors, discrete graphics cards, and gigabytes of memory are generally needed, and it’ll be a long time before something like an off-the-shelf router has all of these components.

But with a specialized distribution of Debian Linux called Proxmox and a healthy amount of configuration it’s possible to flip this idea on its head: getting a desktop computer capable of playing modern video games to take over the network infrastructure for a LAN instead, all with minimal impact to the overall desktop experience. In effect, it’s possible to have a router that can not only play DOOM but play 2020’s DOOM Eternal, likely with hardware most of us already have on hand.

The key that makes a setup like this work is virtualization. Although modern software makes it seem otherwise, not every piece of software needs an eight-core processor and 32 GB of memory. With that in mind, virtualization software splits modern multi-core processors into groups which can act as if they are independent computers. These virtual computers or virtual machines (VMs) can directly utilize not only groups or single processor cores independently, but reserved portions of memory as well as other hardware like peripherals and disk drives.

Proxmox itself is a version of Debian with a number of tools available that streamline this process, and it installs on PCs in essentially the same way as any other Linux distribution would. Once installed, tools like LXC for containerization, KVM for full-fledged virtual machines, and an intuitive web interface are easily accessed by the user to allow containers and VMs to be quickly set up, deployed, backed up, removed, and even sent to other Proxmox installations. Continue reading “Network Infrastructure And Demon-Slaying: Virtualization Expands What A Desktop Can Do” →

Reconductoring: Building Tomorrow’s Grid Today

June 11, 2025 by Dan Maloney 68 Comments

What happens when you build the largest machine in the world, but it’s still not big enough? That’s the situation the North American transmission system, the grid that connects power plants to substations and the distribution system, and which by some measures is the largest machine ever constructed, finds itself in right now. After more than a century of build-out, the towers and wires that stitch together a continent-sized grid aren’t up to the task they were designed for, and that’s a huge problem for a society with a seemingly insatiable need for more electricity.

There are plenty of reasons for this burgeoning demand, including the rapid growth of data centers to support AI and other cloud services and the move to wind and solar energy as the push to decarbonize the grid proceeds. The former introduces massive new loads to the grid with millions of hungry little GPUs, while the latter increases the supply side, as wind and solar plants are often located out of reach of existing transmission lines. Add in the anticipated expansion of the manufacturing base as industry seeks to re-home factories, and the scale of the potential problem only grows.

The bottom line to all this is that the grid needs to grow to support all this growth, and while there is often no other solution than building new transmission lines, that’s not always feasible. Even when it is, the process can take decades. What’s needed is a quick win, a way to increase the capacity of the existing infrastructure without having to build new lines from the ground up. That’s exactly what reconductoring promises, and the way it gets there presents some interesting engineering challenges and opportunities.

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Generating Plasma With A Hand-Cranked Generator

June 10, 2025 by Maya Posch 12 Comments

Everyone loves to play with electricity and plasma, and [Hyperspace Pirate] is no exception. Inspired by a couple of 40×20 N52 neodymium magnets he had kicking around, he decided to put together a hand-cranked generator and use it to generate plasma with. Because that’s the kind of fun afternoon projects that enrich our lives, and who doesn’t want some Premium Fire™ to enrich their lives?

The generator itself is mostly 3D printed, with the magnets producing current in eight copper coils as they spin past. Courtesy of the 4.5:1 gear on the crank side, it actually spins at over 1,000 RPM with fairly low effort when unloaded, albeit due to the omission of iron cores in the coils. This due to otherwise the very strong magnets likely cogging the generator to the point where starting to turn it by hand would become practically impossible.

Despite this, the generator produces over a kilovolt with the 14,700 turns of 38 AWG copper wire, which is enough for the voltage multiplier and electrodes in the vacuum chamber, which were laid out as follows:

Circuit for the plasma-generating circuit with a vacuum chamber & hand-cranked generator. (Credit: Hyperspace Pirate, YouTube)

Some of our esteemed readers may be reminded of arc lighters which are all the rage these days, and this is basically the hand-cranked, up-scaled version of that. Aside from the benefits of having a portable super-arc lighter that doesn’t require batteries, the generator part could be useful in general for survival situations. Outside of a vacuum chamber the voltage required to ionize the air becomes higher, but since you generally don’t need a multi-centimeter arc to ignite some tinder, this contraption should be more than sufficient to light things on fire, as well as any stray neon signs you may come across.

If you’re looking for an easier way to provide some high-voltage excitement, automotive ignition coils can be pushed into service with little more than a 555 timer, and if you can get your hands on a flyback transformer from a CRT, firing them up is even easier.

Continue reading “Generating Plasma With A Hand-Cranked Generator” →

Is The Atomic Outboard An Idea Whose Time Has Come?

June 10, 2025 by Tyler August 48 Comments

Everyone these days wants to talk about Small Modular Reactors (SMRs) when it comes to nuclear power. The industry seems to have pinned its hopes for a ‘nuclear renaissance’ on the exciting new concept. Exciting as it may be, it is not exactly new: small reactors date back to the heyday of the atomic era. There were a few prototypes, and a lot more paper projects that are easy to sneer at today. One in particular caught our eye, in a write-up from Steve Wientz, that is described as an atomic outboard motor.

It started as an outgrowth from General Electric’s 1950s work on airborne nuclear reactors. GE’s proposal just screams “1950s” — a refractory, air-cooled reactor serving as the heat source for a large turboprop engine. Yes, complete with open-loop cooling. Those obviously didn’t fly (pun intended, as always) but to try and recoup some of their investment GE proposed a slew of applications for this small, reactor-driven gas turbine. Rather than continue to push the idea of connecting it to a turboprop and spew potentially-radioactive exhaust directly into the atmosphere, GE proposed podding up the reactor with a closed-cycle gas turbine into one small, hermetically sealed-module. Continue reading “Is The Atomic Outboard An Idea Whose Time Has Come?” →

Turning Up The Heat On HT-PLA’s Marketing

June 9, 2025 by Tyler August 28 Comments

PLA is probably the most-printed filament on the market these days, and is there any wonder? It’s cheap, it’s easy, and it doesn’t poison you (as quickly as its competitors, anyway). What it doesn’t do very well is take the heat. Polymaker’s new HT-PLA formulation promises to solve that, and [My Tech Fun] put those claims to the test in a recent video.

Polymaker claims its HT-PLA is heat-stable up-to 150 C, but still prints as easily as standard PLA at up to 300 mm/s. By “heat stable” they mean able to maintain dimensions and form at that temperature when not under any load, save perhaps its own weight. If you need high-temp mechanical properties, they also offer a glass-fiber infused HT-PLA-GF that they claim is heat resistant up to 110 C (that is, able to withstand load at that temperature) which is hard to sneeze at, considering you you could print it on a stock Ender so long as you tossed a hardened nozzle on it.

Now it’s not a free lunch: to get the very best results, you do need to anneal the parts, which can introduce shrinkage and warping in HT-PLA, but that’s where HT-PLA-GF shines. If you want to see the results of the tests you can jump to 19:27 in the video, but the short version is that this is mechanically like PLA and can take the heat.

The verdict? If you like printing PLA and want to shove something in a hot car, you might want to try HT-PLA. Otherwise, it’s just like PLA. It prints like PLA, it looks like PLA, and when cold it behaves mechanically like PLA, which we suppose was rather what Polymaker was going for. There is no word yet on whether the additives that make it high-temp increase off-gassing or toxicity but since this stuff prints like PLA and can stand a little airflow, it should be easy to ventilate, which might make for fewer trade-offs when building an enclosure.

What do you think, will you be trying HT-PLA anytime soon? Let us know in the comments.

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Nintendo Switch 2 Teardown, Let’s A-Go!

June 9, 2025 by Drew Littrell 12 Comments

A new console challenger has appeared, and it goes by the name Nintendo Switch 2. The company’s latest iteration of the home console portable hybrid initially showed promise by featuring a large 1080p display, though very little official footage of the handheld existed prior to the device’s global release last week. However, thanks to a teardown video from [TronicsFix], we’ve got a little more insight into the hardware.

The technical specifications of this new console have been speculated on for the last handful of years. We now know NVIDIA is again providing the main silicon in the form of a custom 8x ARM Cortex A78C processor. Keeping the system powered is a 5220 mAh lithium ion battery that according to [TronicsFix] is held in with some seriously strong adhesive.

On the plus side for repairability, the onboard microphone and headphone jack are each attached by their own ribbon cable to the motherboard. The magnetic controller interfaces are also modular in design as they may one day prove to be a point of failure from repeated detachment. Speaking of which, [TronicsFix] also took apart the new version of the Joy-Con controller that ships with the system.

Arguably the biggest pain point for owners of the original Nintendo Switch was the reliability of the analog sticks on the diminutive controllers. There were widespread reports of “stick drift” that caused players to lose control as onscreen avatars would lazily move in one direction without player input. For the Switch 2, the Joy-Con controllers feature roughly the same number of dome switch buttons as well as haptic feedback motors. The analog sticks are larger in size on the outside, but feature the same general wiper/resistor design of the original. Many will cry foul of the continued use of conventional analog stick design in favor of hall effect sensors, but only time will tell if the Nintendo Switch 2 will repeat history.

Continue reading “Nintendo Switch 2 Teardown, Let’s A-Go!” →