3D Printing Tiny Metal Parts

It may sound like a pop band, but μ-WAAM is actually a 3D printing technique for making small metal parts from the NOVA University Lisbon. Of course, WAAM stands for wire arc additive manufacturing, a well-known technique for 3D printing in metal. The difference? The new technique uses 250 μm wire stock instead of the 1mm or thicker wires used in conventional WAAM.

The thinner feed wire allows μ-WAAM to create fine details like thin walls that would be difficult to replicate with traditional methods. Typically, for fine structures, printers use fused metal powder. This is good for fine details, but typically slower and has higher waste than wire-based systems.

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Predicting The Future: How’s That Working Out?

With 2022 off to a good start, it is about time to let go of all those New Year’s resolutions that didn’t quite work out. The scale’s needle didn’t reverse, our nails are still bitten, and we are still binge-watching Breaking Bad instead of reading the classics. But, of course, there’s always the future where we just know we’re going to stick to our resolutions. Besides, the future will be replete with fat-eating nanobots, 3D printed nails every morning, and a pill you can take that will make you remember reading Ulysses.

Predicting the future is fraught with peril, which is why launching a new company or product is so risky. However, there have been a few prognosticators that have made some impressive forecasts. For example, in 1922 popular (if not critically acclaimed) author W. L. George wrote a piece for The New York Herald titled “What the World Will be Like In a Hundred Years.” Since May will see that piece’s 100th anniversary, let’s see how he did.

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Featured image of Aladdin's Castle Arcade

Retrotechtacular: Raw Video From Inside A 1980s Arcade

It was just this year that Sega left the arcade business for good. A company synonymous with coin-op games for over a half century completely walked away from selling experiences you can only get on location. No more Outrun or Virtua Fighter machines, because arcades these days tend to resemble The House of the Dead. Arcades still exist to a degree, it’s just that headlines like that serve only as a reminder of an era gone by. Which is what makes raw footage like the video [Jon] posted of an Aladdin’s Castle arcade from the 1980s so compelling.

scan of Aladdin's Castle Arcade pamphlet ad
Aladdin’s Castle ad brochure circa 1983. Credit: John Andersen

The raw VHS footage starts with a sweep around the location’s pinball machines and arcade cabinets. There’s an extended shot of a rare TX-1 tri-monitor sitdown cabinet. The racing game was the first of its kind to feature force feedback in the steering wheel, so it’s no wonder it received the focus. The arcade’s lighting tech was also a point of pride as it allowed for programmable lighting cues. A far cry from the flickering fluorescent tubes no doubt in use elsewhere. Eventually the employee filming takes us to the back room where it the owner has made it abundantly clear that they are not a fan of Mondays, judging by the amount of Garfield merchandise.

Bally’s Aladdin’s Castle was a chain of arcades and had nearly 400 locations across the US at its height in the mid 1980s (at least according to their brochure seen above). Those neon red letters were a mainstay of American shopping malls throughout the decade. Namco, the Pac-Man people, acquired Aladdin’s Castle in 1993 and the brand faded away soon after. Although there is a lone location in Quincy, IL that is still open for business today.

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NASA Taps Lockheed To Bring Back A Piece Of Mars

Since NASA’s Mariner spacecraft made the first up-close observations of Mars in 1964, humanity has lobbed a long line of orbiters, landers, and rovers towards the Red Planet. Of course, it hasn’t all been smooth sailing. History, to say nothing of the planet’s surface, is littered with Martian missions that didn’t quite make the grade. But we’ve steadily been getting better, and have even started to push the envelope of what’s possible with interplanetary robotics through ambitious craft like the Ingenuity helicopter.

Yet, after nearly 60 years of studying our frigid neighbor, all we have to show for our work boils down to so many 1s and 0s. That’s not to say the data we’ve collected, both from orbit and on the surface, hasn’t been extremely valuable. But scientists on Earth could do more with a single Martian rock than any robotic rover could ever hope to accomplish. Even still, not so much as a grain of sand has ever been returned from the planet’s dusty surface.

But if everything goes according to plan, that’s about to change. Within the next decade, NASA and the European Space Agency (ESA) hope to bring the first samples of Martian rocks, soil, and atmospheric gases back to Earth using a series of robotic vehicles. While it’s still unclear when terrestrial scientists should expect delivery of this interplanetary bounty, the first stage of the program is already well underway. The Perseverance rover has started collecting samples and storing them in special tubes for their eventual trip back to Earth. By 2028, another rover will be deployed to collect these samples and load them into a miniature rocket for their trip to space.

Launching the Mars Ascent Vehicle (MAV).

Just last week NASA decided to award the nearly $200 million contract to build that rocket, known officially as the Mars Ascent Vehicle (MAV), to aerospace giant Lockheed Martin. The MAV will not only make history as the first rocket to lift off from a celestial body other than the Earth, but it’s arguably the most critical component of the sample return mission; as any failure during launch will mean the irrevocable loss of all the samples painstakingly recovered by Perseverance over the previous seven years.

To say this mission constitutes a considerable technical challenge would be an understatement. Not only has humanity never flown a rocket on another planet, but we’ve never even attempted it. No matter what the outcome, once the MAV points its nose to the sky and lights its engines, history is going to be made. But while it will be the first vehicle to make the attempt, engineers and scientists have been floating plans for a potential Martian sample return mission for decades. Continue reading “NASA Taps Lockheed To Bring Back A Piece Of Mars”

World's longest hacksaw

Fail Of The Week: A Bigger Hacksaw Isn’t A Better Hacksaw

If we’re being honest, the main reason to buy a power tool is to avoid the pain of using one’s muscles. Oh sure, we dress it up with claims that a power tool will make us more productive, or give better results, but more often than not it’s the memory of how your forearm feels after a day of twisting a screwdriver that makes you buy a cordless driver.

It appears that [Artisan Makes] has a high tolerance for pain, seeing how the main prep tool in his metal shop is a plain old hacksaw. So in an effort to speed up his stock prep, he turned not to a bandsaw or cutoff saw, but instead built the world’s silliest hacksaw. It’s the metalworking equivalent of the two-man bucksaws that lumberjacks used to fell trees before chainsaws came along, and at a meter and half in length, it’s about the size of one too. Modifying the frame of his trusty hacksaw was easy — he just popped the end pieces off and attached them to an extra-long piece of tube stock. Finding a 1.5-meter hacksaw blade was the main challenge; not exactly a big-box store item, that. So a section of metal-cutting bandsaw blade was modified to fit the frame, and it was off to the races.

Or not. The video below tells the tale of woe, which starts with the fact that [Artisan]’s shop is too small for the hilariously long hacksaw. Solving the fixturing problems didn’t soo much to help, though — there was no way to tension the blade enough to get it to stop wobbling during cutting. It was also clear that the huge saw wasn’t able to apply enough downforce on the stock to get good cuts. Maybe with a second set of hands, though…

There are plenty of ways to improve hacksawing in the shop, and while this isn’t one of them, we sure appreciate the chuckle we got out of it. And you really should check out [Artisan Makes]’ channel — his more serious stuff is really good.

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Backpack Board For OLEDs Boasts Fancy Features

Back when LCD character displays based on the HD44780 controller were the bee’s knees, a way to make them easier to work with came in the form of “backpack” PCBs, which provided an accessible serial interface and superior display handling at the same time. [Barbouri] has updated that idea with a backpack board that mounts to OLED displays using the US2066 display driver, and provides an I2C interface with powerful and convenient high-level functions that make the display simple to use.

On the software side, the backpack uses this I2cCharDisplay driver project which provides functions like cursor control, fading, display shifting, and of course writing characters or strings. While [Barbouri] designed the board specifically to accommodate Newhaven Slim Character OLED displays, it should in theory work with any US2066-based OLED character display. [Barbouri]’s design files for the Slim-OLED Display backpack board are available for download directly from the project page (link is near the bottom), or boards can be purchased directly from OSH Park.

OLED technology is nifty as heck; we’ve seen some neat tricks done by stacking transparent OLED displays, and even seen OLEDs made in the home lab.

This Minibike Will Land You In Hot Water

The minibike is an American phenomenon which fascinates those of us from countries in which such contraptions are illegal on the road; they seem to deliver bucketloads of low-octane fun in which we are unable to participate. [HowToLou] has one, and as it’s something for use in the Great Outdoors it naturally requires some means of fixing a brew. His solution to the need for a mug of boiling water in out-of-the-way places? A gravity-fed heat exchanger for the exhaust pipe, fed from a reservoir made using an upturned bottle.

As can be seen in the video below the break it’s a simple enough piece of work but surprisingly effective. A piece of small-bore copper tube is passed through a cork into the bottle, then wrapped round a piece of pipe which forms an exhaust The resulting heat exchanger is insulated, the engine started, and the cork loosened just enough to cause a bit of water to flow. The result – a good flow of hot water for that morning coffee.

It may not be the most practical of water heaters, but it’s certainly a bit of fun even if it might not work with all the minibikes we’ve covered.

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