3D Printering: Managing Multiple Printing Profiles

October 18, 2022 by Al Williams 7 Comments

I know people who have 3D printers that are little more than appliances. They buy it, they print with it, and they don’t change much of anything. That doesn’t describe me and, I’m guessing, it doesn’t describe you either. This does lead to a problem, though, when it comes to slicers. You have to keep changing profiles and modifying them. It can be hard to keep things straight. For example, if you have profiles for different nozzles, you get to make a choice: keep one profile and edit the parts that change, or keep multiple profiles and any common changes have to be propagated to the other profiles.

Part of the reason I want to manage multiple profiles has to do with this mystery object…

I’ve long wanted to create a system that lets me have baseline profiles and then just use specific profiles that change a few items in the baseline. Turns out, I didn’t need to do it. Prusa Slicer and its fork, SuperSlicer, have the capability already. Both of these, of course, are based on Slic3r, but the scripting languages are different and what I’m doing does require G-code scripting. The problem is, this capability is not documented very well and the GUI doesn’t really support it directly, which requires a little sidestepping. I’ll show you how I have things set up and where the limitations are. If you want to try your hand at it, I highly suggest you backup your configuration directory or switch to a new one.

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3D Printing With A Drone Swarm?

October 18, 2022 by Dave Rowntree 14 Comments

Even in technical disciplines such as engineering, there is much we can still learn from nature. After all, the endless experimentation and trials of life give rise to some of the most elegant solutions to problems. With that in mind, a large team of researchers took inspiration from the humble (if rather annoying) wasp, specifically its nest-building skills. The idea was to explore 3D printing of structures without the constraints of a framed machine, by mounting an extruder onto a drone.

As you might expect, one of the most obvious issues with this attempt is the tendency of the drone’s to drift around slightly. The solution the team came up with was to mount the effector onto a delta bot carrier hanging from the bottom of the drone, allowing it to compensate for its measured movement and cancel out the majority of the positional error.

The printing method relies upon the use of two kinds of drone. The first done operates as a scanner, measuring the print surface and any printing already completed. The second drone then approaches and lays down a single layer, before they swap places and repeat until the structure is complete.

Multiple drones can print simultaneously, by flying in formation. Prints were demonstrated using a custom cement-like material, as well as what appeared to be expanding foam, which was impressive feat to say the least.

The goal is to enable the printing of large, complex shaped structures, on any surface, using a swarm of drones, each depositing whatever material is required. It’s a bit like a swarm of wasps building a nest, into whatever little nook they come across, but on the wing.

We’ve been promised 3D printed buildings for some time now, and while we’re not sure this research is going to bring us any closer to living in an extruded house, we’re suckers for a good drone swarm here at Hackaday.

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Mining And Refining: Cobalt, The Unfortunately Necessary Metal

October 18, 2022 by Dan Maloney 21 Comments

The story of humankind is largely a tale of conflict, often brought about by the uneven distribution of resources. For as long as we’ve been down out of the trees, and probably considerably before that too, our ancestors have been struggling to get what they need to survive, as often as not at the expense of another, more fortunate tribe. Food, water, land, it doesn’t matter; if They have it and We don’t, chances are good that there’s going to be a fight.

Few resources are as unevenly distributed across our planet as cobalt is. The metal makes up only a fraction of a percent of the Earth’s crust, and commercially significant concentrations are few and far between, enough so that those who have some often end up at odds with those who need it. And need it we do; what started in antiquity as mainly a rich blue pigment for glass and ceramics has become essential for important industrial alloys, high-power magnets, and the anodes of lithium batteries, among other uses.

Getting access to our limited supply of cobalt and refining it into a useful metal isn’t a trivial process, and unfortunately its outsized importance to technological society forces it into a geopolitical role that has done a lot to add to human misery. Luckily, market forces and new technology are making once-marginal sources viable, which just may help us get the cobalt we need without all the conflict.

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Playdate Handheld Turned Typewriter

October 18, 2022 by Bryan Cockfield 6 Comments

The Playdate is an interesting gaming system. It’s a handheld, has a black and white screen, and superficially reminds us a little bit of the original Game Boy, right down to the button layout. But the fact that it has a second controller that pops out of the side, that this controller is a crank, and that the whole system was made by the same people that made Untitled Goose Game, makes us quite intrigued. Apparently it has made an impact on others, too, because this project turns the gaming system into a typewriter.

The Playdate doesn’t have native support for USB accessories unless it’s plugged into this custom 3D printed dock. Inside of the dock is a Teensy 4.1 which handles some translation between the keyboard and the console. Once the dock is taken care of the text editor needs to be side-loaded to the device as well. The word processor has the ability to move the cursor around, insert and delete text, and the project’s creator, [t0mg], plans to add more features in future versions like support for multiple files, changing the font, and a few other things as well.

For anyone interested in recreating this project, all of the printable files, the text editor, and the schematics are all available in the GitHub repo. It’s an impressive project for a less well-known console that we haven’t seen many other hacks for, unless you count this one-off Arduboy project which took some major inspiration from the Playdate’s crank controller.

Kodak Film Factory Revealed

October 18, 2022 by Dave Walker 51 Comments

Anybody born before the mid 1990s will likely remember film cameras being used to document their early years. Although the convenience of digital cameras took over and were then themselves largely usurped by mobile phones, there is still a surprising variety of photographic film being produced. Despite the long pedigree, how many of us really know what goes into making what is a surprisingly complex and exacting product? [Destin] from SmarterEveryDay has been to Rochester, NY to find out for himself and you can see the second in a series of three hour-long videos shedding light on what is normally the strictly lights-out operation of film-coating.

Kodak first digital camera 1975 — Kodak’s first attempt at a digital camera in 1975. The form-factor still left something to be desired…

Kodak have been around in one form or another since 1888, and have been producing photographic film since 1889. Around the turn of the Millennium, it looked as though digital photography (which Kodak invented but failed to significantly capitalize on) would kill off film for good, and in 2012 Kodak even went into Chapter 11 bankruptcy, which gave it time to reorganize the business.

They dramatically downsized their film production to meet what they considered to be the future demand, but in a twist of fortunes, sales have surged in the last five years after a long decline. So much so, in fact, that Kodak have gradually grown from running a single shift five days per week a few years ago, to a 24/7 operation now. They recently hired 300 Film Technicians and are still recruiting for more, to meet the double-digit annual growth in demand.

[Destin] goes to great lengths to explain the process, including making a 3D model of the film factory, to better visualize the facility, and lots of helpful animations. The sheer number of steps is mind-boggling, especially when you consider the precision required at every step and the fact that the factory runs continuously… in the dark, and is around a mile-long from start to finish. It’s astonishing to think that this process (albeit at much lower volumes, and with many fewer layers) was originally developed before the Wright Brothers’ first powered flight.

We recently covered getting a vintage film scanner to work with Windows 11, and a little while back we showed you the incredible technology used to develop, scan and transmit film images from space in the 1960s.

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A digital caliper connected to a tablet computer

Custom Interface Adds USB And Wi-Fi To Digital Calipers

October 17, 2022 by Robin Kearey 26 Comments

Although old-school machinists typically prefer the mechanical vernier scale on their trusty calipers, many users nowadays buy calipers with a digital readout. These models often come with additional features like differential measurements, or a “hold” function for those situations where you have to maneuver the instrument somewhere deep inside a machine. Another useful feature is a data link that lets you log your measurements on a computer directly instead of manually entering all the values.

The VINCA-branded caliper that [Liba2k] bought has such a data link feature, which requires a USB adapter that’s sold separately. There is a micro-USB connector on the tool itself, but instead of implementing a USB interface, this is used to carry a proprietary serial protocol — a design decision that ought to be classified as a felony if you ask us. Rather than buying the official USB adapter, [Liba2k] decoded the protocol and built his own interface called VINCA Reader that can connect through either USB or Wi-Fi.

The serial format turned out to be a simple serial bus that clocks out 24 bits at a time. In order to adapt its 1.2 V signal level to the 3.3 V used by an ESP32, [Liba2k] designed a simple level shifter circuit using a handful of discrete components. The ESP can communicate with the computer through its Wi-Fi interface, for which [Liba2k] wrote a spreadsheet-like application; alternatively, an ordinary USB cable can be connected to emulate a keyboard for use with any other software.

With its added Wi-Fi feature, the VINCA Reader is actually more complete than the official USB adapter, and will probably be cheaper as well. The serial interface appears to be common to all caliper manufacturers, although many went for a more sensible connector than micro-USB. An automated readout system is particularly handy if you have to make thousands of similar measurements.

An exploded diagram of the spot welder. Shown are the capacitor bank, trigger, 12 V relay, DC power input, power out, step up converter, voltmeter, industrial SCR module, and capacitor bank.

Hackaday Prize 2022: A Not-So-Smart Spot Welder

October 17, 2022 by Navarre Bartz 5 Comments

DIY spot welders often use high-powered components that can be a bit frightening, given the potential for dangerous malfunctions. [Wojciech “Adalbert” J.] designed his capacitive discharge spot welder to be safe, easy to build, and forego the microcontroller.

Many projects work great with just a single Li-ion cell, but when you need more power, you’ve got to start connecting more cells together into a battery. [Wojciech]’s spot welder is designed to be just powerful enough to weld nickel tabs onto a cell without any overkill. The capacitor bank uses nineteen Nichicon UBY 7500uF/35V capacitors, all wired in parallel using solder wick saturated with solder. They sit atop on a perfboard with metallicized holes to carry the high current.

[Wojciech] has detailed every step of building the welder, including changes to the off-the-shelf relay board and adding a potentiometer to the step-up converter board. The level of detail makes this seem like a good starting place if you’re hoping to hop into the world of DIY spot welders. Safe is always a relative term when dealing with high powered devices, so be careful if you do attempt this build!

DIY spot welders have graced these digital pages many times, including this one built with safety in mind, and this other one that was decidedly not.