Inexpensive Powder Coating

March 4, 2025 by 17 Comments

[Pete] had a friend who would powder coat metal parts for him, but when he needed 16 metal parts coated, he decided he needed to develop a way to do it himself. Some research turned up the fluid bed method and he decided to go that route. He 3D printed a holder and you can see how it all turned out in the video below.

A coffee filter holds the powder in place. The powder is “fluidized” by airflow, which, in this case, comes from an aquarium pump. The first few designs didn’t work out well. Eventually, though, he had a successful fluid bed. You preheat the part so the powder will stick and then, as usual, bake the part in an oven to cure the powder. You can expect to spend some time getting everything just right. [Pete] had to divert airflow and adjust the flow rate to get everything to work right.

With conventional powder coating, you usually charge the piece you want to coat, but that’s not necessary here. You could try a few other things as suggested in the video comments: some suggested ditching the coffee filter, while others think agitating the powder would make a difference. Let us know what you find out.

This seems neater than the powder coating guns we’ve seen. Of course, these wheels had a great shape for powder coating, but sometimes it is more challenging.

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Illustrated Kristina with an IBM Model M keyboard floating between her hands.

Keebin’ With Kristina: The One With The Schreibmaschine

March 4, 2025 by 6 Comments

Choc switches on a ThumbsUp! v8 keyboard with IBM Selectric typewriter keycaps, thanks to some 3D-printed adapters.
Image by [Sasha K.] via reddit
Remember that lovely Hacktric centerfold from a couple Keebins ago with the Selectric keycaps? Yeah you do. Well, so does [Sasha K.], who saw the original reddit post and got inspired. [Sasha K.] has more than one IBM Selectric lying around, which is a nice problem to have, and decided to strip one of its keycaps and get to experimenting.

The result is a nice adapter that allows them to be used with Kailh chocs — you can find the file on Thingiverse, and check out the video after the break to see how they sound on a set of clicky white chocs.

Those white chocs are attached to a ThumbsUp! v8 keyboard, a line that [Sasha K.] designed. His daily driver boards are on v9 and v10, but the caps were getting jammed up because of the spacing on those. So instead, he used v8 which has Cherry MX spacing but also supports chocs.

As you can see, there is not much to the adapter, which essentially plugs the Selectric keycap’s slot and splits the force into the electrical outlet-style pair of holes that chocs bear This feels like an easier problem to solve than making an adapter for MX-style switches. What do you think?

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It’s 2025, And Here’s A New Film Format

March 4, 2025 by 8 Comments

We love camera hacking here at Hackaday, and it’s always fascinating to see new things being done in photography. Something rather special has come our way from [Camerdactyl], who hasn’t merely made a camera, instead he’s created an entirely new analogue film format. Move over 35mm and 120, here’s the RA-4 cartridge!

RA-4 is the colour print chemistry many of you will be familiar with from your holiday snaps back in the day. Normally a negative image is projected onto it from the negative your camera took, and the positive image is developed on the paper as the reverse of that.  It can also be developed as a reversal process similar to slide film, in which the negative image is developed and bleached away leaving an unexposed positive image, which can then be exposed to light and developed to reveal a picture. This means that with carefully chosen colour correction filters it can be shot in a camera to make normal colour prints with this reversal process.

The new film format is a 3D printed cartridge system holding a long roll of RA-4 paper, which slots into a back for standard 5 by 4 inch cameras. He’s also made a modular developing machine for the process, and can get over 100 shots on a roll. A portion of the video below deals with how he wants to release it; since it has taken a huge amount of development resources he intends to release the files to the public in stages as he reaches sales milestones with his work. It’s an unusual strategy that we hope works for him, though we suspect that many camera hackers would be prepared to pay him directly for the files.

Either way, it’s a reminder that there’s still plenty of fun to be had with analogue film, and also that reversal development of RA-4 is possible. Some of us here at Hackaday have been known to hack a few cameras, we guess it’s another one to add to the “one day” list.

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LTA’s Pathfinder 1: The Dawn Of A New Age Of Airships?

March 4, 2025 by 32 Comments

Long before the first airplanes took to the skies, humans had already overcome gravity with the help of airships. Starting with crude hot air balloons, the 18th century saw the development of more practical dirigible airships, including hydrogen gas balloons. On 7 January 1785, French inventor, and pioneer of gas balloon flight Jean-Pierre Blanchard would cross the English Channel in such a hydrogen gas balloon, which took a mere 2.5 hours. Despite the primitive propulsion and steering options available at the time, this provided continued inspiration for new inventors.

With steam engines being too heavy and cumbersome, it wasn’t until the era of internal combustion engines a century later that airships began to develop into practical designs. Until World War 2 it seemed that airships had a bright future ahead of them, but amidst a number of accidents and the rise of practical airplanes, airships found themselves mostly reduced to the not very flashy role of advertising blimps.

Yet despite popular media having declared rigid airships such as the German Zeppelins to be dead and a figment of a historic fevered imagination, new rigid airships are being constructed today, with improvements that would set the hearts of 1930s German and American airship builders aflutter. So what is going on here? Are we about to see these floating giants darken the skies once more?

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Cheap Hackable Smart Ring Gets A Command Line Client

March 4, 2025 by 18 Comments

Last year, we’ve featured a super cheap smart ring – BLE, accelerometer, heart sensor, and a battery, all in a tiny package that fits on your finger. Back when we covered it, we expected either reverse-engineering of stock firmware, or development of a custom firmware outright. Now, you might be overjoyed to learn that [Wesley Ellis] has written a Python client for the ring’s stock firmware.

Thanks to lack of any encryption whatsoever, you can simply collect the data from your ring, no pairing necessary, and [Wesley]’s work takes care of the tricky bits. So, if you want to start collecting data from this ring right now, integrate it into anything you want, such as your smart home or exoskeleton project, this client is enough. A few firmware secrets remain – for instance, the specific way that the ring keep track of day phases, or SPO2 intricacies. But there’s certainly enough here for you to get started with.

This program will work as long as your ring uses the QRing app – should be easy to check right in the store listing. Want to pick up the mantle and crack open the few remaining secrets? Everything is open-source, and there’s a notepad that follows the OG reverse-engineering journey, too. If you need a reminder on what this ring is cool for, here’s our original article on it.

CNC Router And Fiber Laser Bring The Best Of Both Worlds To PCB Prototyping

March 4, 2025 by 22 Comments

Jack of all trades, master of none, as the saying goes, and that’s especially true for PCB prototyping tools. Sure, it’s possible to use a CNC router to mill out a PCB, and ditto for a fiber laser. But neither tool is perfect; the router creates a lot of dust and the fiberglass eats a lot of tools, while a laser is great for burning away copper but takes a long time to burn through all the substrate. So, why not put both tools to work?

Of course, this assumes you’re lucky enough to have both tools available, as [Mikey Sklar] does. He doesn’t call out which specific CNC router he has, but any desktop machine should probably do since all it’s doing is drilling any needed through-holes and hogging out the outline of the board, leaving bridges to keep the blanks connected, of course.

Once the milling operations are done, [Mikey] switches to his xTool F1 20W fiber laser. The blanks are placed on the laser’s bed, the CNC-drilled through holes are used as fiducials to align everything, and the laser gets busy. For the smallish boards [Mikey] used to demonstrate his method, it only took 90 seconds to cut the traces. He also used the laser to cut a solder paste stencil from thin brass shim stock in only a few minutes. The brief video below shows the whole process and the excellent results.

In a world where professionally made PCBs are just a few mouse clicks (and a week’s shipping) away, rolling your own boards seems to make little sense. But for the truly impatient, adding the machines to quickly and easily make your own PCBs just might be worth the cost. One thing’s for sure, though — the more we see what the current generation of desktop fiber lasers can accomplish, the more we feel like skipping a couple of mortgage payments to afford one.

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It’s SSB, But Maybe Not Quite As You Know It

March 3, 2025 by 17 Comments

Single Sideband, or SSB, has been the predominant amateur radio voice mode for many decades now. It has bee traditionally generated by analogue means, generating a double sideband and filtering away the unwanted side, or generating 90 degree phase shifted quadrature signals and mixing them. More recent software-defined radios have taken this into the CPU, but here’s [Georg DG6RS] with another method. It uses SDR techniques and a combination of AM and FM to achieve polar modulation and generate SSB. He’s provided a fascinating in-depth technical explanation to help understand how it works.

The hardware is relatively straightforward; an SI5351 clock generator provides the reference for an ADF4351 PLL and VCO, which in turn feeds a PE4302 digital attenuator. It’s all driven from an STM32F103 microcontroller which handles the signal processing. Internally this means conventionally creating I and Q streams from the incoming audio, then an algorithm to generate the phase and amplitude for polar modulation. These are fed to the PLL and attenuator in turn for FM and AM modulation, and the result is SSB. It’s only suitable for narrow bandwidths, but it’s a novel and surprisingly simple deign.

We like being presented with new (to us at least) techniques, as it never pays to stand still. Meanwhile for more conventional designs, we’ve got you covered.