How To Create Hermetically Sealed Electrical Connections

[Eric Strebel] is no stranger to pressure and vaccum tanks, regularly using them for all manner of resin casting jobs for his product design business. However, sometimes it becomes necessary to run equipment within a pressure tank, such as for rotomoulding or other similar jobs. In order to get power into a tank under pressure, [Eric] built a special plug with a hermetic seal to do the job. (Video, embedded below.)

The build starts with a large metal plug which screws into the pressure vessel, into which a square recess is machined. For the electrical passthrough, [Eric] selected GX-16 aviation connectors, in this case packing six conductors. The connectors are hooked up back-to-back through the hole in the metal tank plug, using bare copper wire. This is to avoid insulation on wires acting as a channel for gases to pass through. With the connectors wired up and an acrylic disc in place to stop overflow, the metal plug is filled with resin to create the hermetic seal.

Results are good, with the connectors functioning electrically and the resin acting as a perfect seal. There’s a small risk of short circuit with the exposed copper conductors, but [Eric] is exploring some easy solutions to avoid issues. We’ve seen his work before, too – like this great discussion on cardboard as a design tool. Video after the break.

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Hackaday Podcast 084: Awful Floppy Disk Music, Watching A Robot Climb Walls, A Futuristic Undersea Lab, And Inside A Digital Pregnancy Test

With Editor in Chief Mike Szczys off this week, Managing Editor Elliot Williams is joined by Staff Writer Dan Maloney to look over the hacks from the last week. If you’ve ever wondered how the Beatles sound on a floppy disk, wonder no more. Do you fear the coming robopocalypse? This noisy wall-climbing robot will put those fears to rest. We’ll take a look at an undersea lab worthy of the Cousteau name, and finally we’ll look inside a digital pregnancy test and wonder at its unusual power switch.

Take a look at the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

Take a look at the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

Direct download (60 MB or so.)

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Cousteau’s Proteus Will Be The ISS Of The Seas

The Earth’s oceans are a vast frontier that brims with possibilities for the future of medicine, ocean conservation, and food production. They remain largely unexplored because of the physical limits of scuba diving. Humans can only dive for a few hours each day, and every minute spent breathing compressed air at depth must be paid for with a slower ascent to the surface. Otherwise, divers could develop decompression sickness from nitrogen expanding in the bloodstream.

An illustration of the Conshelf 3 habitat. Image via Medium

In the 1960s, world-famous oceanographer Jacques Cousteau built a series of small underwater habitats to extend the time that he and other researchers were able to work. These sea labs were tethered to a support ship with a cable that provided air and power.

Cousteau’s first sea lab, Conshelf 1 (Continental Shelf Station) held two people and was stationed 33 feet deep off the coast of Marseilles, France. Conshelf 2 sheltered six people and spent a total of six weeks under the Red Sea at two different depths.

Conshelf 3 was Cousteau’s most ambitious habitat design, because it was nearly self-sufficient compared to the first two. It accommodated six divers for three weeks at a time and sat 336 feet deep off the coast of France, near Nice. Conshelf 3 was built in partnership with a French petrochemical company to study the viability of stationing humans for underwater oil drilling (before we had robots for that), and included a mock oil rig on the nearby ocean floor for exercises.

Several underwater habitats have come and gone in the years since the Conshelf series, but each has been built for a specific research project or group of tasks. There’s never really been a permanent habitat established for general research into the biochemistry of the ocean.

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Fog-Free Mask Hack Solves Mask Versus Glasses Conundrum With Superb Seal

If you have worn a mask and glasses together for more than a quarter of a second, you are probably annoyed that we don’t have a magical solution for foggy lenses. Moisture-laden air is also a good indicator of where unfiltered air is escaping. Most masks have some flexible metal across the nose bridge that is supposed to seal the top, but it is woefully inadequate. The Badger Seal by [David Rothamer] and [Scott Sanders] from the University of Wisconsin-Madison College of Engineering is free to copy during the COVID-19 pandemic, even commercially. It works by running an elastic cord below the jaw and a formable wire over the nose to encourage contact all around both mouth and nose.

You can build your own in three ways. Each configuration is uniquely suited to a different situation. The first design is the easiest to make and should work for most people. The second is best for folks who need a better seal on the lower half of their face, like someone sporting a beard. It can also have ear loops, and that means your 3D printed ear savers have another use. The Madison campus of the University of Wisconsin also has fun with lock cracking and graphene experiments.
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Geocaching On Mars: How Perseverance Will Seal Martian Samples With A Return To Earth In Mind

With the roughly 20-day wide launch window for the Mars 2020 mission rapidly approaching, the hype train for the next big mission to the Red Planet is really building up steam. And with good reason — the Mars 2020 mission has been in the works for a better part of a decade, and as we reported earlier this year, the rover it’s delivering to the Martian surface, since dubbed Perseverance, will be among the most complex such devices ever fielded.

“Percy” — come on, that nickname’s a natural — is a mobile laboratory, capable of exploring the Martian surface in search of evidence that life ever found a way there, and to do the groundwork needed if we’re ever to go there ourselves. The nuclear-powered rover bristles with scientific instruments, and assuming it survives the “Seven Minutes of Terror” as well as its fraternal twin Curiosity did in 2012, we should start seeing some amazing results come back.

No prior mission to Mars has been better equipped to answer the essential question: “Are we alone?” But no matter how capable Perseverance is, there’s a limit to how much science can be packed into something that costs millions of dollars a kilogram to get to Mars. And so NASA decided to equip Perseverance with the ability to not only collect geological samples, but to package them up and deposit them on the surface of the planet to await a future mission that will pick them up for a return trip to Earth for further study. It’s bold and forward-thinking, and it’s unlike anything that’s ever been tried before. In a lot of ways, Perseverance’s sample handling system is the rover’s raison d’être, and it’s the subject of this deep dive.

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Hackaday Podcast 077: Secret Life Of SD Cards, Mining Minecraft’s Secret Seed, BadPower Is Bad, And Sailing A Sea Of Neon

Hackaday editors Mike Szczys and Elliot Williams are deep in the hacks this week. What if making your own display matrix meant a microcontroller board for every pixel? That’s the gist of this incredible neon display. There’s a lot of dark art poured into the slivers of microSD cards and this week saw multiple hacks digging into the hidden test pads of these devices. You’ve heard of Folding@Home, but what about Minecraft@Home, the effort to find world seeds from screenshots. And when USB chargers have exposed and rewritable firmware, what could possibly go wrong?

Take a look at the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

Take a look at the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

Direct download (60 MB or so.)

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Hackaday Podcast 067: Winking Out Of IoT, Seas Of LEDs, Stuffing PCBs, And Vectrex Is Awesome

Hackaday editors Mike Szczys and Elliot Williams explore the coolest hacks of the past 168 hours. The big news this week: will Wink customers pony up $5 a month to turn their lights on and off? There’s a new open source design for a pick and place machine. You may not have a Vectrex gaming console, but there’s a scratch-built board that can turn you oscilloscope into one. And you just can’t miss this LED sign technology that programs every pixel using projection mapping.

Take a look at the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

Direct download (60 MB or so.)

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