Japan To Launch Wooden Satellites

December 30, 2020 by 48 Comments

We may have wooden satellites in just a few years, according to an announcement this month by Kyoto University and Sumitomo Forestry, organizations whose combined roots go back 550 years.

Wood’s place in high-technology has a long track record. During World War 2, wooden boats were used for minesweepers, the Spruce Goose was designed to circumvent wartime material restrictions, and Britain’s plywood-built De Havilland Mosquito had a very low radar cross section. In this century, a man in Bosnia has even built a Volkswagen Beetle out of oak.

The newly-announced aerospace project, led by retired astronaut and engineer Prof Takao Doi, plans to launch satellites built from wood in order to reduce space debris and hazardous substances resulting from re-entry. We’re somewhat skeptical on the hazardous substances angle (and we’re not alone in this), but certainly as a way to help ensure complete burn up upon re-entry, wood is an interesting material. It also achieves a great strength to weight ratio and as a renewable resource it’s easy to source.

Prof Doi has been studying the use of wood in space for several years now. Back in 2017 he began basic research on the usability of timbers in space (pg 16), where his team experimented with coniferous (cedar and cypress) and hardwood (satinwood, magnolia, and zelkova) trees in vacuum environments. Based on successes, they predicted wooden satellite launches in the mid 2020s (their announcement this month said 2023). Sumitomo engineers have not released what kind of wood(s) will finally be used on the satellite.

You might remember Astronaut Doi from an experiment aboard the ISS where he successfully demonstrated flying a boomerang in space (video below), and he’s also discovered two supernovae in his spare time. We wish him good luck.

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Remembering Chuck Yeager: The Supersonic Legend Whose Wings Were Clipped By A High School Diploma

December 10, 2020 by 37 Comments

In history there are people whose legacy becomes larger than life. Ask anyone who built and flew the first airplane, and you’d be hard-pressed to find someone who isn’t at least aware of the accomplishments of the Wright brothers. In a similar vein, Chuck Yeager’s pioneering trip into supersonic territory with the Bell X-1 airplane made his name essentially synonymous with the whole concept of flying faster than the speed of sound. This wasn’t the sole thing he did, of course: he also fought in WWII and Vietnam and worked as an instructor and test pilot, flying hundreds of different airplanes during his career.

Yeager’s insistence on making that first supersonic flight, despite having broken two ribs days earlier, became emblematic of the man himself: someone who never let challenges keep him from exploring the limits of the countless aircraft he flew, while inspiring others to give it their best shot. Perhaps ironically, it could be said that the only thing that ever held Yeager back was only having a high school diploma.

On December 7, 2020, Chuck Yeager died at the age of 97, leaving behind a legacy that will continue to inspire many for decades to come.

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Larry Berg And The Purple Open Passion Project

November 18, 2020 by 31 Comments

It all started with an 88-ton Arburg RP300 injection molding machine in the basement, and a bit of inattention. Larry Berg wanted a couple custom plastic plugs for his Garmin GPS, so he milled out a mold and ran a few. But he got distracted, and came back an hour later to find that his machine had made 400. Instead of throwing them away, he mailed them away for free, but then he found that people started throwing money at him to make more. People all over the world.

This is how the Purple Open Project turned into an global network of GPS geeks, selling molded alternatives to the oddball Garmin plugs for pledges to pay an unspecified amount, and ended up producing over 350,000 plugs over 16 years before he passed away in 2012. This is the story of a hacker’s hacker, who wanted to be able to connect his GPS to his computer and use it the way he wanted, and accidentally created an international business.

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Sending 3D Printed Parts To Mars: A Look Inside JPL’s Additive Manufacturing Center

November 10, 2020 by 5 Comments

With the Mars 2020 mission now past the halfway point between Earth and its destination, NASA’s Jet Propulsion Lab recently released a couple of stories about the 3D-printed parts that made it aboard the Perseverance rover. Tucked into its aeroshell and ready for its high-stakes ride to the Martian surface, Perseverance sports eleven separate parts that we created with additive manufacturing. It’s not the first time a spacecraft has flown with parts made with additive manufacturing technique, but it is the first time JPL has created a vehicle with so many printed parts.

To take a closer look at what 3D-printing for spaceflight-qualified components looks like, and to probe a little into the rationale for additive versus traditional subtractive manufacturing techniques, I reached out to JPL and was put in touch with Andre Pate, Additive Manufacturing Group Lead, and Michael Schein, lead engineer on one of the mission’s main scientific instruments. They both graciously gave me time to ask questions and geek out on all the cool stuff going on at JPL in terms of additive manufacturing, and to find out what the future holds for 3D-printing and spaceflight.

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Crowd Funded Jumping Cubes

October 30, 2020 by 5 Comments

The Japan Aerospace Exploration Agency (JAXA) recently contributed their Int-Ball  technology to a Kickstarter campaign operated by the Japanese electronics manufacturer / distributor Bit Trade One (Japanese site). This technology is based on the Cubli project out of the Swiss Federal Institute of Technology in Zurich (ETH Zurich), which we covered back in 2013. The Cubli-based technology has been appearing in various projects since then, including the Nonlinear Mechatronic Cube in 2016.  Alas, the current JAXA-based “3-Axis Attitude Control Module” project doesn’t have a catchy name — yet.

One interesting application of these jumping cubes, presumably how JAXA got involved with these devices, is a floating video camera that was put to use on board the International Space Station (ISS) in 2017.  The version being offered by the Kickstarter campaign doesn’t include the cameras, and you will need to provide your own a gravity-free environment to duplicate that application.  Instead, they seem to be marketing this for educational uses.  You’d better dig deep in your wallet if you want one — a fully assembled unit requires a pledge of over $5000 ( there is a “some assembly required” kit that can save you about $1000 ).  Most of us won’t be backing this project for that reason alone, but it is nice to see the march of progress of such a cool technology:  from inception to space applications to becoming available to the general public.  Thanks to [Lincoln Uehara] for sending in this tip.

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Bringing High Temperature 3D Printing To The Masses

October 28, 2020 by 77 Comments

Despite the impressive variety of thermoplastics that can be printed on consumer-level desktop 3D printers, the most commonly used filament is polylactic acid (PLA). That’s because it’s not only the cheapest material available, but also the easiest to work with. PLA can be extruded at temperatures as low as 180 °C, and it’s possible to get good results even without a heated bed. The downside is that objects printed in PLA tend to be somewhat brittle and have a low heat tolerance. It’s a fine plastic for prototyping and light duty projects, but it won’t take long for many users to outgrow its capabilities.

The next step up is usually polyethylene terephthalate glycol (PETG). This material isn’t much more difficult to work with than PLA, but is more durable, can handle higher temperatures, and in general is better suited for mechanical parts. If you need greater durability or higher heat tolerance than PETG offers, you could move on to something like acrylonitrile butadiene styrene (ABS), polycarbonate (PC), or nylon. But this is where things start to get tricky. Not only are the extrusion temperatures of these materials greater than 250 °C, but an enclosed print chamber is generally recommended for best results. That puts them on the upper end of what the hobbyist community is generally capable of working with.

Industrial 3D printers like the Apium P220 start at $30,000.

But high-end industrial 3D printers can use even stronger plastics such as polyetherimide (PEI) or members of the polyaryletherketone family (PAEK, PEEK, PEKK). Parts made from these materials are especially desirable for aerospace applications, as they can replace metal components while being substantially lighter.

These plastics must be extruded at temperatures approaching 400 °C, and a sealed build chamber kept at >100 °C for the duration of the print is an absolute necessity. The purchase price for a commercial printer with these capabilities is in the tens of thousands even on the low end, with some models priced well into the six figure range.

Of course there was a time, not quite so long ago, where the same could have been said of 3D printers in general. Machines that were once the sole domain of exceptionally well funded R&D labs now sit on the workbenches of hackers and makers all over the world. While it’s hard to say if we’ll see the same race to the bottom for high temperature 3D printers, the first steps towards democratizing the technology are already being made.

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Teardown: BlackBerry Smart Card Reader

September 28, 2020 by 22 Comments

Years before Steve Jobs showed off the first iPhone, the BlackBerry was already the must-have accessory for mobile professionals. Back then, nobody was worried about watching movies or playing the latest games on their mobile devices, they just wanted a secure and fast way to send and receive email on the go. For that, the BlackBerry was king.

Fast forward to today, and the company is just a shell of what it once was. They don’t even bother making their own hardware anymore. Over the last several years they’ve opted to partner with a series of increasingly obscure manufacturers to produce a handful of lackluster Android phones so they still have something to sell to their dwindling userbase. Anyone excited about the new 5G BlackBerry being built by Texas start-up OnwardMobility? Did you even know it was in the works before now?

A DoD Common Access Card

But this article isn’t about BlackBerry phones. It’s about something that’s even more irrelevant to consumers: the BlackBerry Smart Card Reader. Technically, this little device isn’t dependent on the phones of the same name, but it makes sense that Research In Motion (which eventually just renamed itself to BlackBerry Limited) would market the gadget under the brand of their most popular product. Though as you might expect, software was available to allow it to work with the BlackBerry phone that you almost certainly owned if you needed a dedicated smart card reader.

For those who might not be aware, a smart card in this context is a two-factor authentication token contained in an ID card. These are used extensively by organizations such as the Department of Defense, where they’re known as Common Access Cards, that require you to insert your ID card into a reader before you can log into a secure computer system. This sleek device was marketed as a portable reader that could connect to computers over USB or Bluetooth. Worn around your neck with the included lanyard, the battery-powered reader allowed the card itself to remain on the user’s body while still being readable by nearby devices.

Civilians will recognize the basic technology from modern “Chip and PIN” debit and credit cards, but we’ve never had to stick one of those into our laptop just to log in. To be sure, the BlackBerry Smart Card Reader was never intended for the average home computer user, it was sold to companies and organizations that had tight security requirements; which just so happened to be the same places that would likely already be using BlackBerry mobile devices.

Of course, times and technology change. These devices once cost $200 apiece and were purchased in vast quantities for distribution to trusted personnel, but are now all but worthless. Even in new and unopened condition, they can be had for as little as $10 USD on eBay. For that price, it’s certainly worth taking a peek inside. Perhaps the hacker community can even find new applications for these once cutting-edge devices.

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