Lost Foam Casting In Action

May 19, 2024 by 19 Comments

Even though not all of us will do it, many of us are interested in the art of casting metal. It remains a process that’s not out of reach, though, especially for metals such as aluminium whose melting points are reachable with a gas flame. The video below the break takes us through the aluminium casting process by showing us the lost-foam casting of a cylinder head for a BSA Bantam motorcycle.

The foam pattern is CNC milled to shape, and the leftover foam swarf is removed with a hot wire. The pattern is coated with a refractory coating of gypsum slurry, and the whole is set up in a tub packed with sand. We get the impression that the escaping gasses make this a tricky pour without an extra sprue, and indeed, they rate it as not perfect. The cooling fins on the final head are a little ragged, so it won’t be the part that goes on a bike, but we can see with a bit of refining, this process could deliver very good results.

For this pour, they use a gas furnace, but we’ve seen it done with a microwave oven. Usually, you are losing wax, not foam, but the idea is the same.

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[Scott Manley] Explains GPS Jamming

May 19, 2024 by 45 Comments

We always think of [Scott Manley] as someone who knows a lot about rockets. So, if you think about it, it isn’t surprising he’s talking about GPS — after all, the system uses satellites. GPS is used in everything these days, and other forms of navigation are starting to fall by the wayside. However, the problem is that the system is vulnerable to jamming and spoofing. This is especially important if you fear GPS allowing missiles or drones to strike precise targets. But there are also plenty of opportunities for malicious acts. For example, drone light shows may be subject to GPS attacks from rival companies, and you can easily imagine worse. [Scott] talks about the issues around GPS spoofing in the video, which you can see below.

Since GPS satellites are distant, blocking the signal is almost too easy, sometimes happening inadvertently. GPS has technology to operate in the face of noise and interference, but there’s no way to prevent it entirely. Spoofing — where you produce false GPS coordinates — is much more difficult.

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This WiFi Filament Sensor Is Unnecessary, But Awesome

May 19, 2024 by 3 Comments

As desktop 3D printers have inched towards something resembling the mainstream, manufacturers have upped their game across the board. Even the quality of filament that you can get today is far better than what was on the market in the olden days, back when a printer made out of laser-cut birch wasn’t an uncommon sight at the local makerspace. Now, even the cheap rolls are wound fairly well and are of a consistent diameter. For most folks, you just need to pick a well-reviewed brand, buy a roll, and get printing.

But as with everything else, there are exceptions. Some people are producing their own filaments, or want to make sure their extrusion rate is perfectly calibrated. For those that need the capability, the WInFiDEL from [Sasa Karanovic] can detect filament diameter in real-time while keeping the cost and complexity as low as possible. Even better, with both the hardware and software released as open source, it makes an excellent starting point for further development and customization.

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Möbius String Robot Goes Round And Round

May 19, 2024 by 9 Comments

While it doesn’t look like a traditional robot, the hydrogel robot from [Zi Liang Wu] forms a möbius strip and can be activated by light. They also experimented with shaping the hydrogels as a Seifert ribbon.

The key is that the hydrogels contain gold nanoparticles. Light heats the gold particles and this causes the hydrogels to move. The connections between the strips of hydrogels causes them to move in predictable ways. You can see a video about the experiments below.

These robots aren’t going to be for warehouse or factory work. But they can do tasks like collecting plastic beads, something difficult for conventional robots to do. They also hope to demonstrate that these soft robots could work in the body for taking samples or delivering a drug, although it isn’t apparent how light would get to them inside your body.

The dark side of the material tends to turn towards the light. The continuous loop structure means it never runs to the end of its travel. Watching it move on a string is pretty impressive.

Crawling and slithering robots may be the answer for certain specialized applications. After all, it works well in nature.

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M1 Development Board From Scraps

May 18, 2024 by 29 Comments

Apple is fairly notorious for building devices that are difficult to repair, but with the right tools it’s often not completely impossible to circumvent some of their barriers. As they say, every lock has a key. [dosdude1] has wanted a specific M1 development board for a while now and has been slowly piecing together everything he needs to cobble one together, and finally got this unit running despite many roadblocks put in his way by Apple.

The development kit is a Developer Transition Kit  or “DTK” meant for developers during Apple’s transition from Intel chips to their own in-house ARM-based M1 platform. This particular version is in a Mac Mini form factor but it has a few hurdles to clear before it powers on. First, the board was cut in a critical location that shorted out many of the PCB layers, so this had to be carefully filed down to remove the shorts. It was also missing a few tiny surface mount components and a NAND chip, but these were scavenged from other scrapped parts and assembled into a fully working machine.

There are a number of other non-physical problems to solve here as well, too. Apple coded their NAND chips to work with specific WiFi modules so if these aren’t programmed to work together the computer will get stuck in a boot loop. But with that and a few other details out of the way [dosdude1] finally has his DTK up and running in a 2018 Mac Mini chassis, right down to the working power LEDs. We’ve seen all kinds of PCB damage before (although not often quite this intricate) and even PCBs repaired that were snapped in half.

Thanks to [CodeAsm] for the tip!

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Students’ Leaf Blower Suppressor To Hit Retail

May 18, 2024 by 81 Comments

Electric leaf blowers are already far quieter than their gas-powered peers, but they still aren’t the kind of thing you’d like to hear first-thing on a Saturday morning. Looking to improve on the situation, a group of students from Johns Hopkins University have successfully designed a 3D printed add-on that manages to significantly reduce the noise generated by a modern electric leaf blower without compromising the amount of air it’s able to move. The device has proven to be so successful in tests that Stanley Black & Decker is looking to put a commercial version of the device on store shelves within the next two years.

The team says the first part of the problem was identifying where the noise was actually coming from. After taking an example leaf blower apart and studying all of its moving components, they determined that most of the noise produced wasn’t mechanical at all — what you’re actually hearing is the complex cacophony of high-speed air rushing out of the nozzle. With this knowledge in hand, they isolated the frequencies which were the harshest to the human ear and focused on canceling them out.

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Flexures Keep This Printed Displacement Sensor In Line

May 18, 2024 by 4 Comments

When the job at hand is measuring something with micron-range precision, thoughts generally turn to a tool with a Mitutoyo or Starrett nameplate. But with a clever design and a little electronics know-how, it turns out you can 3D print a displacement sensor for measuring in the micron range for only about $10.

While the tool that [BubsBuilds] came up with isn’t as compact as a dial indicator and probably won’t win any industrial design awards, that doesn’t detract from its usefulness. And unlike a dial indicator — at least the analog type — this sensor outputs an easily digitized signal. That comes courtesy of a simple opto-interrupter sensor, which measures the position of a fine blade within its field of view. The blade is attached to a flexure that constrains its movement to a single plane; the other end of the flexure has a steel ball acting as a stylus. In use, any displacement of the stylus results in more or less light being received by the phototransistor in the opto-interrupter; the greater the deflection, the less light and the lower the current through the transistor. In addition to the sensor itself, [Bub] printed a calibration jig that allows precision gauge blocks or simple feeler gauges to be inserted in front of the stylus. The voltage across the emitter resistor for these known displacements is then used to create a calibration curve.

[Bub] says he’s getting 5-micron repeatability with careful calibration and multiple measurements of each gauge block, which seems pretty impressive to us. If you don’t need the digital output, this compliant mechanism dial indicator might be helpful too. Continue reading “Flexures Keep This Printed Displacement Sensor In Line” →