Learn How Impossibly Close-fitting Parts Are Actually Made

May 17, 2023 by 15 Comments

Most of us have seen those demonstrations of metal parts that mate together so finely that, once together, they have no visible seam at all. But how, exactly, is this done? [Steve Mould] has a video that shows and explains all, and we’ve never seen the process explained quite like he does.

The secret ingredient is wire EDM, or Electrical Discharge Machining, but that’s only one part of the whole. Wire EDM works a bit like a hot-wire cutter slicing through foam, but all by itself that’s not enough to produce those impossibly close-fitting parts we love to see.

EDM is capable of astounding precision in part because — unlike a cutting tool — nothing physically contacts the material. Also, there isn’t a lot of friction and heat causing small distortions of the material during the machining process. EDM is as a result capable of fantastically-precise cuts, but not invisible ones.

It’s pretty neat to see a water jet used to thread the fine wire through the workpiece.

In all good manufacturing, the capabilities (and limitations) of the tool are taken into account, and this is also true for making those close-fitting pieces. The hole and plug are actually made in two separate stages.

The hole is cut separately from the plug, and because EDM is capable of such finesse, the cuts can be made in such a way that they complement one another with near-perfection. After that, grinding and polishing takes care of the surface finish. The result is the fantastically-smooth and apparently seamless fitment we like so much.

The video is embedded below, and there are some great details about EDM and how it actually works in there. For example, we see how a wire EDM machine can use a jet of water to help thread the wire through a hole in the part to start a job, and we learn that the wire is constantly moving during the process.

As cool as wire EDM is, it is not magic and we’ve seen some pretty remarkable efforts at bringing the technology into the home workshop.
Continue reading “Learn How Impossibly Close-fitting Parts Are Actually Made” →

Two Factor Authentication Apps: Mistakes To Malware

May 17, 2023 by 58 Comments

Everyone in security will tell you need two-factor authentication (2FA), and we agree. End of article? Nope. The devil, as always with security, is in the details. Case in point: in the last few weeks, none less than Google messed up with their Google Authenticator app. The security community screamed out loud, and while it’s not over yet, it looks like Google is on the way to fixing the issue.

Since 2FA has become a part of all of our lives – or at least it should – let’s take a quick dip into how it works, the many challenges of implementing 2FA correctly, what happened with Google Authenticator, and what options you’ve got to keep yourself safe online.

Continue reading “Two Factor Authentication Apps: Mistakes To Malware” →

Mythic I: An Exploration Of Artisanal Computing

May 17, 2023 by 14 Comments

While computers have become ever faster and more capable over the years, it’s hard to say they’ve become any more exciting. In fact, they’ve become downright boring. Desktop, laptop, or mobile, they’re all more or less featureless slabs of various dimensions. There’s not even much in the way of color variation — the classic beige box is now available with white, black, or metallic finishes.

Believing that such a pedestrian appearance isn’t befitting a device that puts the world’s collected knowledge at our fingertips, [Keegan McNamara] started exploring a more luxurious approach to computing. Gone is the mass produced injection molded plastic, in its place is hand-carved maple and Tuscan leather. Common computing form factors are eschewed entirely for a swooping console inspired by fine furniture and classic sports cars. The final result, called the Mythic I, is equal parts art and science. Not just a bold reimaging of what a computer can be, but an object to be displayed and discussed. Continue reading “Mythic I: An Exploration Of Artisanal Computing” →

Cornering The Antenna Market

May 17, 2023 by 21 Comments

Sometimes antennas can seem like black magic. However, when you see things like a dish antenna, it sort of makes sense, right? Just like a mirror focuses light, the parabola of a dish focuses RF energy. But [IMSAI Guy] shows another common-sense antenna arrangement: a corner reflector dipole. He had built one years ago and decided to do a bit of research and make another one.

In a clever use of copper-clad board, he was able to make a reasonable reflector by soldering together three boards and an RF connector. A single wire makes the “driven element,” and by bending it to just the right position, you can change the characteristic impedance for matching.

The antenna, in this case, is essentially a quarter-wave antenna with a ground plane and reflector arrangement. After the obligatory chalk talk, he breaks out the vector network analyzer and shows how well it matches. He didn’t, however, measure the gain or directional selectivity due to the reflector.

Intuitively, you’d think this kind of antenna would be good for direction finding purposes. In fact, hams that use handy talkies for direction finding often use their bodies to block signals, much like these reflectors should.

The [IMSAI Guy] reflector is pretty small, but you can easily make bigger ones. Using PCB material for antennas isn’t anything new, either, but we still enjoyed this simple corner reflector build.

Continue reading “Cornering The Antenna Market” →

Self-Driving Library For Python

May 16, 2023 by 3 Comments

Fully autonomous vehicles seem to perennially be just a few years away, sort of like the automotive equivalent of fusion power. But just because robotic vehicles haven’t made much progress on our roadways doesn’t mean we can’t play with the technology at the hobbyist level. You can embark on your own experimentation right now with this open source self-driving Python library.

Granted, this is a library built for much smaller vehicles, but it’s still quite full-featured. Known as Donkey Car, it’s mostly intended for what would otherwise be remote-controlled cars or robotics platforms. The library is built to be as minimalist as possible with modularity as a design principle, and includes the ability to self-drive with computer vision using machine-learning algorithms. It is capable of logging sensor data and interfacing with various controllers as well, either physical devices or through something like a browser.

To build a complete platform costs around $250 in parts, but most things needed for a Donkey Car compatible build are easily sourced and it won’t be too long before your own RC vehicle has more “full self-driving” capabilities than a Tesla, and potentially less risk of having a major security vulnerability as well.

Human DNA Is Everywhere: A Boon For Science, While Terrifying Others

May 16, 2023 by 15 Comments

Environmental DNA sampling is nothing new. Rather than having to spot or catch an animal, instead the DNA from the traces they leave can be sampled, giving clues about their genetic diversity, their lineage (e.g. via mitochondrial DNA) and the population’s health. What caught University of Florida (UoF) researchers by surprise while they were using environmental DNA sampling to study endangered sea turtles, was just how much human DNA they found in their samples. This led them to perform a study on the human DNA they sampled in this way, with intriguing implications.

Ever since genetic sequencing became possible there have been many breakthroughs that have made it more precise, cheaper and more versatile. The argument by these UoF researchers in their paper in Nature Ecology & Evolution is that although there is a lot of potential in sampling human environmental DNA (eDNA) to study populations much like is done today already with wastewater sampling, only more universally. This could have great benefits in studying human populations much how we monitor other animal species already using their eDNA and similar materials that are discarded every day as a part of normal biological function. Continue reading “Human DNA Is Everywhere: A Boon For Science, While Terrifying Others” →

MIDI Interface For NeXTcube Plugs Into The Past

May 16, 2023 by 21 Comments

[Joren] recently did some work as part of an electronic music heritage project, and restored an 80s-era NeXTcube workstation complete with vintage sound card, setting it up with a copy of MAX, a graphical music programming environment. But there was one piece missing: MIDI. [Joren] didn’t let that stop him, and successfully created hardware to allow MIDI input and output.

The new panel provides all the connectors necessary to interface with either classic MIDI devices, or MIDI over USB (where it appears as a USB MIDI device to any modern OS.)

Interestingly, the soundcard for the NeXTcube has an RS-422 serial port and some 8-pin mini DIN connectors. They are not compatible with standard MIDI signals, but they’re not far off, either.

To solve this, [Joren] used a Teensy developer board to act as an interface between classic MIDI devices like keyboards or synthesizers (or even not-so-common ones like this strange instrument) while also being able to accommodate modern MIDI over USB connections thanks to the Teensy’s USB MIDI functionality.

A metal enclosure with a 3D-printed panel rounds out the device, restoring a critical piece of functionality to the electronic music-oriented workstation.

MIDI as a protocol isn’t technically limited to musical applications, though that’s one place it shines. And just in case it comes in handy someday, you can send MIDI over I2C if you really need to.