Multi-Material Printing Enables Low Cost Silicone Prototypes

September 4, 2024 by 9 Comments

While it’s the ideal choice for mass production, injection molding is simply no good for prototyping. The molds are expensive and time-consuming make, so unless you’ve got the funding to burn tens of thousands of dollars on producing new ones each time you make a tweak to your design, they’re the kind of thing you don’t want to have made until you’re absolutely sure everything is dialed in and ready. So how do you get to that point without breaking the bank?

That’s not always an easy question, but if you’re working with silicone parts, the team at OpenAeros thinks they might have a solution for you. As demonstrated through their OpenRespirator project, the team has developed a method of 3D printing single-use molds suitable for large silicone parts that they’re calling Digital-to-Silicone (D2S).

In the video below, [Aaron] and [Jon] explain that they started off by simply printing injection molds in the traditional style. This worked, but the molds can get quite complex, and the time and effort necessary to design and print them wasn’t a great fit for their iterative development cycle. They wanted to be able to do from design to prototype in a day, not a week.

Eventually they realized that if they printed the mold out of a water-soluble filament, they could simplify its design greatly. They’ve documented the design process in detail, but the short version is that you essentially subtract the 3D model of the design you want to produce from a solid shape in your CAD package, and add a few holes for injecting the silicone. Once the silicone has cured, the mold can be dissolved away in warm water to reveal the finished part.

They then took this concept a step further. Thanks to the multi-material capabilities offered by some of the latest 3D printers, it’s possible to print structures within the mold. Once the silicone is injected, these structures can become part of the finished part. For the OpenRespirator, this lets them add PETG stiffening rings around where the filters to snap into the silicone mask body.

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OpenSCAD Library Creates QR Codes On The Fly

September 4, 2024 by 18 Comments

If you’ve been reading Hackaday for awhile, you’ll know we’re big fans of OpenSCAD around these parts. There’s a number of reasons it’s a tool we often reach for, but certainly one of the most important ones is its parametric nature. Since you’re already describing the object you want to generate with code and variables, it’s easy to do things like generate an arbitrary number of cloned objects by using a for loop.

There are a number of fantastic OpenSCAD libraries that explore this blurred line between code and physical objects, and one that recently caught our eye is scadqr from [xypwn]. The description says it lets you “Effortlessly generate QR codes directly in OpenSCAD”, and after playing around with it for a bit, we have to agree.

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College Gives You Practical Electronics

September 3, 2024 by 28 Comments

While classroom learning isn’t for everyone, one awesome benefit of the Internet is that you have a variety of college classes available to you, even if they aren’t for credit. You can virtually audit classes from institutions around the world on just about any topic you can think of. Of course, the topic we think of is practical electronics and that happens to be the title of a class from [Dr. Bill Newhall] of the University of Colorado. You can watch the first part in the video below. So far, there are two lectures available but more are coming as the class is ongoing right now.

[Dr. Newhall] is one of us. He’s a ham radio operator and a pilot, as well as an electrical engineer. This class is aimed at others who need to understand electronics in another context. It reminded us of the genesis of one of our favorite books — also from a professor — The Art of Electronics.

The course material promises to cover topics ranging from solar and battery power sources, power conversions, IoT and RF communications, sensors, and DC motor control. Of course, there will also be sections on microcontrollers and associated hardware.

Just like a real class, the first lecture has a lot of housekeeping information, but you might want to skim it anyway. But if you want to get to the electronics, the second video won’t disappoint. While it covers a lot of ground that is probably familiar to most Hackaday readers, it is a good review and there’s more coming in the future lectures.

With all the resources online, you can easily hack your own degree plan together. Having access to instructors like [Dr. Newhall] is exactly the point we were making about how the Internet allows you to leverage the best educational opportunities no matter where you are.

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A Nibble Of Core Memory, In An SAO

September 3, 2024 by 14 Comments

Core memory, magnetized memory using tiny magnetic rings suspended on a grid of wires, is now more than five decades obsolete, yet it exerts a fascination for hardware hackers still. Not least [Andy Geppert], who’s made a nibble, four bits of it, complete with interactive LED illumination to show state. Best of all, it’s on a badge Simple Add-On (SAO) for fun and games at your next hacker con.

Aside from it being a fun project, perhaps the most interesting part comes in the GitHub repository, where can be found the schematic for the device. He’s built all the drive and sense circuitry himself rather than finding an old-stock core memory driver chip, which gives those of us who’ve never worked with this stuff the chance to understand how it works. Beyond that it takes input from the Stemma or SAO ports to a GPIO expander, which provides all the lines necessary to drive it all.

To show it in action he’s posted a video which we’ve placed below. If you’re hungry for more, it’s not [Andy]’s first outing into core memory.

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A small handheld word game called Batch Craze, where one player tries to get another to guess the word on the screen.

2024 Tiny Games Contest: Batch Craze Is Portable Charades, Kind Of

September 3, 2024 by No comments

So there’s this commercial electronic game out there called Catch Phrase, which, as the game’s own catch phrase explains, is the game that’s played one word at a time. See, a word comes up on the screen, and you have to get the other person or team to guess what it is using gestures and such before the timer goes off. There are a bunch of rules, like you can’t say a word that rhymes, give the first letter, or the number of syllables.

Well, [ahixson1230] and company got their hands on the After Dark NSFW version but found it lacking in the edginess department. So naturally, [ahixson1230] was inspired to build a better one, with a touch screen in lieu of buttons, and a way for players to suggest words to be added to the list. In this version, a player presses anywhere on the screen to start the game, and a random word or phrase comes up. They act it out, get the other person to guess, and then pass the unit over to continue the fun.

Batch Craze is based on the Cheap Yellow Display, aka the ESP32-2432S028R, and [ahixson1230] highly recommends [witnessmenow]’s excellent resource on the subject. As of this writing, [ahixson1230] is still trying to get the speaker to work, and welcomes any help. Can you assist?

There’s still time to enter the 2024 Tiny Games Contest! You have until Tuesday, September 10th, so head on over to Hackaday.IO and get started!

2024 Tiny Games Challenge

A Clean Linux Installation For An Android TV Box

September 3, 2024 by 22 Comments

Although Android technically runs on top of Linux, generally most Android devices abstract away the underlying Linux-ness of these machines. In theory this is a good thing; we wouldn’t necessarily want to live in a world where we have to log in to a command-line interface just to make a phone call. But too much abstraction often needlessly restricts the capabilities of the underlying hardware. [Murray] a.k.a [Green Bug-Eyed Monster] has an Android TV box with just such a problem, as the Android OS included with it allows for watching TV just fine, but with a few tweaks it can run a full Linux installation instead, turning it into a much more versatile machine.

This specific Android TV box is based on the Rockchip 3566, a popular single-board computer used in a wide array of products. As such it is one of the easier targets for transforming a limited TV machine into a fully capable desktop computer. The first step is to compile an Armbian image for the machine, in this case using an x86 installation of Ubuntu to cross-compile for the ARM-based machine. With a viable image in hand, there’s an option to either solder on a microSD slot to the included pins on the computer’s PCB or to flash the image directly to the on-board eMMC storage by tricking the machine into thinking that the eMMC is missing. Either option will bring you into a full-fledged Linux environment, with just a few configuration steps to take to get it running like any other computer.

[Murray] began this process as an alternative to paying the inflated prices of Raspberry Pis over the past few years, and for anyone in a similar predicament any computer with the Rockchip 3566 processor in it could be a potential target for a project like this. You might need to make a few tweaks to the compile options and hardware, but overall the process should be similar. And if you don’t have an RK3566, don’t fret too much. We’ve seen plenty of other Android TV boxes turned into similar devices like this one which runs RetroPie instead.

Mowing The Lawn With Lasers, For Science

September 3, 2024 by 34 Comments
Cutting grass with lasers works great in a test setup. (Credit: Allen Pan, YouTube)

Wouldn’t it be cool if you could cut the grass with lasers? Everyone knows that lasers are basically magic, and if you strap a diode laser or two to a lawn mower, it should slice through those pesky blades of grass with zero effort. Cue [Allen Pan]’s video on doing exactly this, demonstrating in the process that we do in fact live in a physics-based universe, and lasers are not magical light sabers that will just slice and dice without effort.

The first attempt to attach two diode lasers in a spinning configuration like the cutting blades on a traditional lawn mower led to the obvious focusing issues (fixed by removing the focusing lenses) and short contact time. Effectively, while these diode lasers can cut blades of grass, you need to give them some time to do the work. Naturally, this meant adding more lasers in a stationary grid, like creating a Resident Evil-style cutting grid, only for grass instead of intruders.

Does this work? Sort of. Especially thick grass has a lot of moisture in it, which the lasers have to boil off before they can do the cutting. As [Allen] and co-conspirator found out, this also risks igniting a lawn fire in especially thick grass. The best attempt to cut the lawn with lasers appears to have been made two years ago by [rctestflight], who used a stationary, 40 watt diode laser sweeping across an area. When placed on a (slowly) moving platform this could cut the lawn in a matter of days, whereas low-tech rapidly spinning blades would need at least a couple of minutes.

Obviously the answer is to toss out those weak diode lasers and get started with kW-level chemical lasers. We’re definitely looking forward to seeing those attempts, and the safety methods required to not turn it into a laser safety PSA.

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