Most complex blinking light

2025 One Hertz Challenge: 16-Bit Tower Blinks At One Hertz

July 23, 2025 by 3 Comments

We’ve seen our share of blinking light projects around here; most are fairly straightforward small projects, but this entry to the 2025 One Hertz Challenge is the polar opposite of that approach. [Peter] sent in this awesome tower of 16bit relay CPU power blinking a light every second.

There’s a lot to take in on this project, so be sure to go look at the ongoing logs of the underlying 16-bit relay CPU project where [Peter] has been showing his progress in creating this clicking and clacking masterpiece. The relay CPU consists of a stack of 5 main levels: the top board is the main control board, the next level down figures out the address calculations for commands, under that is the arithmetic logic unit level, under the ALU is the output register where you’ll see a 220 V lamp blinking at 1 Hz, and finally at the base are a couple of microcontrollers used for a clock signal and memory. [Peter] included oscilloscope readings showing how even with the hundreds of moving parts going on, the light is blinking within 1% of its 1 Hz goal.

It’s worth noting that while [Peter] has the relay CPU blinking a light in this setup, the CPU has 19 commands to program it, enabling much more complex tasks. Thanks for the amazing-sounding entry from [Peter] for our One Hertz Challenge. Be sure to check out some of the other relay computers we’ve featured over the years for more clicking goodness.

2025 Hackaday One Hertz Challenge

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Diffuse glow of red, green, and blue LEDs embedded in silicone

Embedded LEDs For Soft Robots Made From Silicone

July 23, 2025 by 3 Comments

Over on their YouTube channel [Science Buddies] shows us how to embed LEDs in soft robots. Soft robots can be made entirely or partially from silicone. In the video you see an example of a claw-like gripper made entirely from silicone. You can also use silicone to make “skin”. The skin can stretch, and the degree of stretch can be measured by means of an embedded sensor made from stretchy conductive fabric.

As silicone is translucent if you embed LEDs within it when illuminated they will emit diffuse light. Stranded wire is best for flexibility and the video demonstrates how to loop the wires back and forth into a spring-like shape for expansion and contraction along the axis which will stretch. Or you can wire in the LEDs without bending the wires if you run them along an axis which won’t stretch.

The video shows how to make silicone skin by layering two-part mixture into a mold. A base layer of silicone is followed by a strip of conductive fabric and the LED with its wires. Then another layer of silicone is applied to completely cover and seal the fabric and LED in place. Tape is used to hold the fabric and LED in place while the final layer of silicone is applied.

When the LEDs are embedded in silicone there will be reduced airflow to facilitate cooling so be sure to use a large series resistor to limit the current through the LED as much as possible to prevent overheating. A 1K series resistor would be a good value to try first. If you need the LED to be brighter you will need to decrease the resistance, but make sure you’re not generating too much heat when you do so.

If you’re interested in stretchy circuits you might also like to read about flexible circuits built on polyimide film.

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The Death Of Industrial Design And The Era Of Dull Electronics

July 23, 2025 by 187 Comments

It’s often said that what’s inside matters more than one’s looks, but it’s hard to argue that a product’s looks and its physical user experience are what makes it instantly recognizable. When you think of something like a Walkman, an iPod music player, a desktop computer, a car or a TV, the first thing that comes to mind is the way  that it looks along with its user interface. This is the domain of industrial design, where circuit boards, mechanisms, displays and buttons are put into a shell that ultimately defines what users see and experience.

Thus industrial design is perhaps the most important aspect of product development as far as the user is concerned, right along with the feature list. It’s also no secret that marketing departments love to lean into the styling and ergonomics of a product. In light of this it is very disconcerting that the past years industrial design for consumer electronics in particular seems to have wilted and is now practically on the verge of death.

Devices like cellphones and TVs are now mostly flat plastic-and-glass rectangles with no distinguishing features. Laptops and PCs are identified either by being flat, small, having RGB lighting, or a combination of these. At the same time buttons and other physical user interface elements are vanishing along with prominent styling, leaving us in a world of basic geometric shapes and flat, evenly colored surfaces. Exactly how did we get to this point, and what does this mean for our own hardware projects?

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Annealing In Space: How NASA Saved JunoCam In Orbit Around Jupiter

July 23, 2025 by 16 Comments

The Juno spacecraft was launched towards Jupiter in August of 2011 as part of the New Frontiers series of spacecraft, on what would originally have been a 7-year mission, including a nearly 5 year cruise to the planet. After a mission extension, it’s currently orbiting Jupiter, allowing for many more years of scientific data to be gathered using its instruments. One of these instruments is the JunoCam (JCM), a visible light camera and telescope. Unfortunately the harsh radiation environment around Jupiter had led many to believe that this camera would fail before long. Now it seems that NASA engineers have successfully tested a fix.

Location of the Juno spacecraft's science instruments. (Credit: NASA)
Location of the Juno spacecraft’s science instruments.

Although the radiation damage to JCM was obvious a few dozen orbits in – and well past its original mission’s 34 orbits – the big question was exactly what was being damaged by the radiation, and whether something could be done to circumvent or fix it. The good news was that the image sensor itself was fine, but one of the voltage regulators in JCM’s power supply was having a bad time. This led the engineers to try annealing the affected part by cranking up one of the JCM’s heaters to a balmy 25°C, well above what it normally is kept at.

This desperate step seemed to work, with massively improved image quality on the following orbits, but soon the images began to degrade again. Before an approach to Jupiter’s moon Io, the engineers thus tried it again but this time cranked the JCM’s heater up to eleven and crossed their fingers. Surprisingly this fixed the issue over the course of a week, until the JCM seems as good as new. Now the engineers are trying their luck with Juno‘s other instruments as well, with it potentially providing a blueprint for extending the life of spacecraft in general.

Thanks to [Mark Stevens] for the tip.

A red, cuboid electrochemical cell is in the center of the picture, with a few wires protruding from the front. Tubes run from each side of the cell to a peristaltic pump and tank on each side. The frame holding the pumps and tanks is white 3D printed plastic.

An Open Source Flow Battery

July 23, 2025 by 28 Comments

The flow battery is one of the more interesting ideas for grid energy storage – after all, how many batteries combine electron current with fluid current? If you’re interested in trying your hand at building one of these, the scientists behind the Flow Battery Research Collective just released the design and build instructions for a small zinc-iodide flow battery.

The battery consists of a central electrochemical cell, divided into two separated halves, with a reservoir and peristaltic pump on each side to push electrolyte through the cell. The cell uses brass-backed grafoil (compressed graphite sheets) as the current collectors, graphite felt as porous electrodes, and matte photo paper as the separator membrane between the electrolyte chambers. The cell frame itself and the reservoir tanks are 3D printed out of polypropylene for increased chemical resistance, while the supporting frame for the rest of the cell can be printed from any rigid filament.

The cell uses an open source potentiostat to control charge and discharge cycles, and an Arduino to control the peristaltic pumps. The electrolyte itself uses zinc chloride and potassium iodide as the main ingredients. During charge, zinc deposits on the cathode, while iodine and polyhalogen ions form in the anode compartment. During discharge, zinc redissolves in what is now the anode compartment, while the iodine and polyhalogen ions are reduced back to iodides and chlorides. Considering the stains that iodide ions can leave, the researchers do advise testing the cell for leaks with distilled water before filling it with electrolyte.

If you decide to try one of these builds, there’s a forum available to document your progress or ask for advice. This may have the clearest instructions, but it isn’t the only homemade flow cell out there. It’s also possible to make these with very high energy densities.

Nylon-Like TPU Filament: Testing CC3D’s 72D TPU

July 22, 2025 by 6 Comments

Another entry in the world of interesting FDM filaments comes courtesy of CC3D with their 72D TPU filament, with [Dr. Igor Gaspar] putting it to the test in his recent video. The use of the Shore hardness D scale rather than the typical A scale is a strong indication that something is different about this TPU. The manufacturer claims ‘nylon-like’ performance, which should give this TPU filament much more hardness and resistance to abrasion. The questions are whether this filament lives up to these promises, and whether it is at all fun to print with.

The CC3D 72D TPU filament used to print a bicycle's handlebar. (Credit: My Tech Fun, YouTube)
The CC3D 72D TPU filament used to print a bicycle’s handlebar grips. (Credit: My Tech Fun, YouTube)

TPU is of course highly hydrophilic, so keeping the filament away from moisture is essential. Printing temperature is listed on the spool as 225 – 245°C, and the filament is very bendable but not stretchable. For the testing a Bambu Lab X-1 Carbon was used, with the filament directly loaded from the filament dryer. After an overnight print session resulted in spaghetti due to warping, it was found that generic TPU settings  at 240ºC with some more nylon-specific tweaks seemed to give the best results, with other FDM printers also working well that way.

The comparison was against Bambu Lab’s 68D TPU for AMS. Most noticeable is that the 72D TPU easily suffers permanent deformation, while being much more wear resistant than e.g. PLA. That said, it does indeed seem to perform more like polyamide filaments, making it perhaps an interesting alternative there. Although there’s some confusion about whether this TPU filament has polyamide added to it, it seems to be pure TPU, just like the Bambu Lab 68D filament.

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A cylindrical red furnace is in the center of the image. To the left of it is a black power supply. A stand is in front of the furnace, with an arm extending over the furnace. To the right of the furnace, a pair of green-handled crucible tongs sit on an aluminium pan.

The Hall-Héroult Process On A Home Scale

July 22, 2025 by 8 Comments

Although Charles Hall conducted his first successful run of the Hall-Héroult aluminium smelting process in the woodshed behind his house, it has ever since remained mostly out of reach of home chemists. It does involve electrolysis at temperatures above 1000 ℃, and can involve some frighteningly toxic chemicals, but as [Maurycy Z] demonstrates, an amateur can now perform it a bit more conveniently than Hall could.

[Maurycy] started by finding a natural source of aluminium, in this case aluminosilicate clay. He washed the clay and soaked it in warm hydrochloric acid for two days to extract the aluminium as a chloride. This also extracted quite a bit of iron, so [Maurycy] added sodium hydroxide to the solution until both aluminium and iron precipitated as hydroxides, added more sodium hydroxide until the aluminium hydroxide redissolved, filtered the solution to remove iron hydroxide, and finally added hydrochloric acid to the solution to precipitate aluminium hydroxide. He heated the aluminium hydroxide to about 800 ℃ to decompose it into the alumina, the starting material for electrolysis.

To turn this into aluminium metal, [Maurycy] used molten salt electrolysis. Alumina melts at a much higher temperature than [Maurycy]’s furnace could reach, so he used cryolite as a flux. He mixed this with his alumina and used an electric furnace to melt it in a graphite crucible. He used the crucible itself as the cathode, and a graphite rod as an anode. He does warn that this process can produce small amounts of hydrogen fluoride and fluorocarbons, so that “doing the electrolysis without ventilation is a great way to poison yourself in new and exciting ways.” The first run didn’t produce anything, but on a second attempt with a larger anode, 20 minutes of electrolysis produced 0.29 grams of aluminium metal.

[Maurycy]’s process follows the industrial Hall-Héroult process quite closely, though he does use a different procedure to purify his raw materials. If you aren’t interested in smelting aluminium, you can still cast it with a microwave oven.