This Tiny Steam Engine Takes A Watchmaker’s Skill To Build

September 9, 2024 by 29 Comments

When your steam engine build requires multiple microscopes, including those of the scanning electron variety, you know you’re building something really, really tiny.

All of the usual tiny superlatives and comparisons apply to [Chronova Engineering]’s latest effort — fits on a pencil eraser, don’t sneeze while you’re working on it or you’ll never find it. If we were to put the footprint of this engine into SMD context, we’d say it’s around a 2010 or so. As one would expect, the design is minimalistic, with no room for traditional bearings or valves. The piston and connecting rod are one piece, meaning the cylinder must pivot, which provides a clever way of switching between intake and exhaust. Tiny crankshaft, tiny flywheel. Everything you’d associate with a steam engine is there, but just barely.

The tooling needed to accomplish this feat is pretty impressive too. [Chronova] are no strangers to precision work, but this is a step beyond. Almost everything was done on a watchmaker’s lathe with a milling attachment and a microscope assist. For the main body of the engine, a pantograph engraving machine was enlisted to scale a 3D printed template down tenfold. Drill bits in the 0.3 mm range didn’t fare too well against annealed tool steel, which is where the scanning electron microscope came into play. It revealed brittle fractures in the carbide tool, which prompted a dive down the rabbit hole of micro-machining and a switch to high-speed steel tooling.

It all worked in the end, enough so that the engine managed 42,000 RPM on a test with compressed air. We eagerly await the equally tiny boiler for a live steam test.

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A photo of a farmer in Kazakhstan wearing a balaclava mask standing in front of a farm house with a rusting piece of Soyuz space capsule used as part of the farm's animal feed trough

One Giant Steppe For Space Flight

September 9, 2024 by 16 Comments

In a recent photo essay for the New Yorker magazine, author Keith Gessen and photographer Andrew McConnell share what life is like for the residents around the launch facility and where Soyuz capsules land in Kazakhstan.

Read the article for a brief history of the Baikonur spaceport and observations from the photographer’s fifteen visits to observe Soyuz landings and the extreme separation between the local farmers and the facilities built up around Baikonur. A local ecologist even compares the family farmers toiling around the busy spaceport to a scene our readers may be familiar with on Tatooine.

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Supercon 2023: Ben Combee And The Hacker’s Guide To Audio/Video Formats

September 9, 2024 by 8 Comments

Media formats have come a long way since the early days of computing. Once upon a time, the very idea of even playing live audio was considered a lofty goal, with home computers instead making do with simple synthesizer chips instead. Eventually, though, real audio became possible, and in turn, video as well.

But what of the formats in which we store this media? Today, there are so many—from MP3s to MP4s, old-school AVIs to modern *.h264s. Senior software engineer Ben Combee came down to the 2023 Hackaday Supercon to give us all a run down of modern audio and video formats, and how they’re best employed these days.

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The Science Of Coating Steel

September 9, 2024 by 6 Comments

[Breaking Taps] has a look at “parkerization” — a process to coat steel to prevent rust. While you commonly see this finish in firearms, it is usable anywhere you need some protection for steel parts. The process is relatively easy. It does require heat and a special manganese solution made for the purpose. You scuff up the surface of the steel and degrease and wash it.

Once the part is ready, you insert the part in hot solution which is manganese and phosphoric acid. Rinse and displace the water and you are ready to oil the part.

But what we really liked was the electron micrographs of the steel before and after the process. The phosphates formed in the solution cover the iron and hold oil to prevent oxidization. However, the first attempt wasn’t uniform so it wouldn’t work as well. [Breaking Taps] thinks it was a failure to rough up the piece sufficiently before starting. He also raised the temperature of the bath and got a better, but not perfect, result.

We miss having an electron microscope at work and we really want one at home! The last fun coating project we remember used copper in a strange and wonderful way.

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Reinforcing Plastic Polymers With Cellulose And Other Natural Fibers

September 9, 2024 by 10 Comments

While plastics are very useful on their own, they can be much stronger when reinforced and mixed with a range of fibers. Not surprisingly, this includes the thermoplastic polymers which are commonly used with FDM 3D printing, such as polylactic acid (PLA) and polyamide (PA, also known as nylon). Although the most well-known fibers used for this purpose are probably glass fiber (GF) and carbon fiber (CF), these come with a range of issues, including their high abrasiveness when printing and potential carcinogenic properties in the case of carbon fiber.

So what other reinforcing fiber options are there? As it turns out, cellulose is one of these, along with basalt. The former has received a lot of attention currently, as the addition of cellulose and similar elements to thermopolymers such as PLA can create so-called biocomposites that create plastics without the brittleness of PLA, while also being made fully out of plant-based materials.

Regardless of the chosen composite, the goal is to enhance the properties of the base polymer matrix with the reinforcement material. Is cellulose the best material here?

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Orion Ceases Operations, Future Of Meade Unclear

September 9, 2024 by 27 Comments

There was a time when building a telescope was a rite of passage for budding astronomers, much as building a radio was the coming age for electronics folks. These days, many things are cheaper to buy than build, even though we do enjoy building anything we can. Orion was a big name in telescopes for many years. Their parent company also owned Meade and Coronado, both well-known optical brands. A recent video from [Reflactor] brought it to our attention that Orion abruptly ceased operations on July 9th.

We always hate to hear when well-known brands that serve a big part of our community vanish. According to [Reflactor], people who have telescopes with the company for repair are likely to never see them again. [Dylan O’Donnell] also had a video about it (see below), and, as he notes, at that time, the website was still operating, but it’s gone now. To add further fuel to the fire Sky & Telescope ran an article on July 12th saying that Meade was also on the chopping block, although at the time of this writing, their site is still online.

You have to wonder what problems you might have selling telescopes today. Many people live where there is light pollution. We’d like to think there are still people who want to ponder the universe from their backyard, though.

There are still people selling telescopes, so presumably, one of them — maybe Celestron — will take up the slack. Or maybe we’ll see a resurgence in telescope homebrewing.

After all, if you have a 3D printer, you could make a 114/900 mm telescope on a tight budget. Or, try IKEA.

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Microsoft Sculpt Keyboard Lives Again With RP2040

September 9, 2024 by 8 Comments

Hackaday readers are likely the kind of folks that have a favorite keyboard, so you can probably imagine how devastating it would be to find out that the board you’ve sworn by for years is going out of production. Even worse, the board has some internal gremlins that show up after a few years of use, so functional ones in the second-hand market are becoming increasingly rare. So what do you do?

This is the position [TechBeret] recently found himself in with his beloved Sculpt keyboard. When Microsoft decided to step back from the peripheral market last year, he started looking at alternatives. Finding none of them appealing, he decided instead to breathe new life into the ergonomic keyboard with the RP2040. Every aspect of the resurrection is covered in a phenomenally detailed write-up on his blog, making this a valuable case study in modernizing peripherals with the popular microcontroller.

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