bolt with maze threads

Maze Bolt Toy By Lost PLA Casting

May 5, 2022 by 8 Comments

Maze bolts, a bolt which has a maze along its shaft traversed by a pin on its nut, are great fun. Here’s a really beautiful metal version by [Robinson Foundry], made by a process more makers should know about – lost PLA casting.

His basic method is to 3D print in PLA, and then use more or less the same process as lost wax casting.

He 3D printed the part, along with the sprues and risers that go along with casting, in PLA, then dipped the parts in slurry ten (10) times.  He heated in a kiln to 500°F (260°C), the PLA melted and ran out or burned away. With the PLA gone, after repairing a few cracks, he raised the temperature to 1500°F (815°C) and vitrified the slurry into a ceramic. He now had molds.

The nut is bronze. The bolt is aluminum.  He poured the metal with the molds hot, held in heated sand, so the metal can flow into all the small details. The rest of the project is just cleanup, but we learned that you can vary the finish produced by glass bead blasting just by varying the air pressure.

A great demo of a useful technique and a fun toy at the end.

We covered a great technique for doing lost PLA casting using a microwave.

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Toast Keyboard Raises A Glass To Short Index Fingers

May 5, 2022 by 4 Comments

Custom keyboards? They’re totally great. And we can keep telling you this, but you really won’t feel it until you try a few and find one or two that are right for you. If you’re already on board, we wonder: is there any limit to what custom keyboards can provide in terms of a good, comfortable time for your fingers, wrists, arms, shoulders, and neck? We think not, and as time goes on, there is more and more evidence to support this.

Take [vpzed]’s Toast keyboard for example. The beauty of customization is that as with any other human input problem, you’ll discover many more people who share your misery once you present a solution. In this case, it is the portion of the population whose index fingers are shorter than their ring fingers (which is evidently men in general). This is known as the 2D:4D ratio and is decided during gestation. At first, the phenomenon was thought to be due to high testosterone exposure in the womb, but subsequent studies have debunked this belief.

Toast aims to sate the need for a keyboard layout that accounts for a significantly shorter 2D than 4D by way of aggressively staggering the index finger’s key positions and staggering the columns overall. As you might imagine, there are no inner keys for length-challenged index fingers to grasp at — that would just be cruel. But there is another pinky column on each hand, which bring the key total to 34. We like the square boards, and frankly wish they were bread-shaped.

Not enough keys for you? Take a look at this many-keyed monoblock split with a numpad in the middle.

via KBD

A vape pen, broken into parts, all laid out on a cutting mat

2022 Hackaday Prize: Disposable Vape Pens Turned Project Parts

May 5, 2022 by 50 Comments

Disposable vape pens, a sub-genre of electronic cigarettes, have been a fad for a few years now – they’re small self-contained devices with a rechargeable battery and some vape liquid inside. As the battery discharges and the liquid runs out, the entire vape pen is typically thrown out. [Dimitar] wants to change that, however, and teaches us how to reuse as much of the vape pen as possible — as yet another underappreciated source for parts we can use in our projects.

In an extensive worklog, he breaks down and documents a vape pen’s inner workings, coupled with a video we’ve placed below the break showing ways to disassemble them. In these, he shows how we can reuse the casing and the plastic parts, should any of us be interested in a project that happens to fit the e-cig form factor. Attention is paid to the sensor that triggers the evaporation — it may look like a microphone, but is actually a purpose-built pressure-sensor with a high-side switch! He tears into one of these in a separate video, showing how to reuse it as a capacitive touch controller. He also aiming to assemble a small database of related resources on GitHub, currently, hosting the files for the protection circuit he developed as part of his recommendations for safely reusing vape pen Li-ion batteries.

[Dimitar]’s journey is ongoing, and we can’t wait to see some fun uses for these components that he will certainly stumble upon on his way! For instance, here’s a hacker using an e-cig battery to power a pair of RGB LED-adorned sunglasses, replacing the AAAA battery they originally came with. We’ve seen hackers make guides on reusing each and every part of microwave ovens, printers and laptops, and we ourselves have talked about reusing ATX power supplies and computer mice.

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A Minimal Motoring Manifesto

May 5, 2022 by 103 Comments

A couple of years ago, Hackaday published an article, “Electric Vehicles Continue the Same Wasteful Mistakes That Limit Longevity“, in which we took a look at the way the car industry, instead of taking the move to electric traction as an opportunity to simplify their products, was instead making their electric offerings far more complex. It touched a nerve and received a very large comment volume, such that now it is our 19th most commented story of all time.

It’s something brought back to the fore by seeing a The Drive piece bemoaning the evolution of the automobile as a software receptacle governed by end-user licenses rather than a machine under the control of its owner. In turn that’s posed the question: Just what do you really need for a car, and what is superfluous? Time to provide an answer to that question, so here it is: a minimal motoring manifesto. Continue reading “A Minimal Motoring Manifesto” →

2022 Hackaday Prize Enters Second Round: Reuse, Recycle, Revamp

May 5, 2022 by 8 Comments

Ding! That’s the bell for the second challenge round of the 2022 Hackaday Prize. If your project reuses or recycles what would otherwise be waste materials, or helps you to do the same for further projects, we want to see it.

Hackers are often frugal folk — we’ll recycle parts for projects because it’s easier on the pocketbook when prototyping. But in these strangest of times, when we’ve seen $1 microcontrollers in such shortage that they fetch $57 apiece (if you can get the parts at all), making use of what you’ve got on hand can be an outright necessity. If this is going to become the new normal, it’s going to make sense that we automate it. There’s gold, literally and metaphorically, in busted PCBs. How are you going to get the most value out of our broken electronic waste in our post-apocalyptic near future? Have you built an unpick-and-unplace machine? We’d like to see it.

But electronic parts are a small fraction of your recyclable materials, and plastics might play a larger role. If you’re a 3D printerer, you’ve doubtless thought about recycling plastic bottles into filament. Or maybe you’d like to take some of the existing plastics that are thrust upon you by this modern world and give them a second life? This factory churning out paving stones by remelting plastic with sand is doing it on an industrial scale, but could this be useful for the home gamer? Precious Plastic has a number of inspirational ideas. Or maybe you just need an HDPE hammer?

Have you built a fancy can crusher, or a plastics sorter, or a recycling robot? Head on over to Hackaday.io, write it up, and enter it into the Prize!

Basically any project that helps you recycle or reuse the material around you is fair game here. (But note that if you’ve got epic repair hacks, you’ll want to enter them in the upcoming Round Three: Hack it Back.) This round runs until June 12th and there are ten $500 awards up for grabs, so get hacking!

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About As Cold As It Gets: The Webb Telescope’s Cryocooler

May 5, 2022 by 26 Comments

If you were asked to name the coldest spot in the solar system, chances are pretty good you’d think it would be somewhere as far as possible from the ultimate source of all the system’s energy — the Sun. It stands to reason that the further away you get from something hot, the more the heat spreads out. And so Pluto, planet or not, might be a good guess for the record low temperature.

But, for as cold as Pluto gets — down to 40 Kelvin — there’s a place that much, much colder than that, and paradoxically, much closer to home. In fact, it’s only about a million miles away, and right now, sitting at a mere 6 Kelvin, the chunk of silicon at the focal plane of one of the main instruments aboard the James Webb Space telescope makes the surface of Pluto look downright balmy.

The depth of cold on Webb is all the more amazing given that mere meters away, the temperature is a sizzling 324 K (123 F, 51 C). The hows and whys of Webb’s cooling systems are chock full of interesting engineering tidbits and worth an in-depth look as the world’s newest space telescope gears up for observations.

Continue reading “About As Cold As It Gets: The Webb Telescope’s Cryocooler” →

Photo of the spectrophotometer in question, with a screenshot of the decoding software on the right

Exporting Data From Old Gear Through LCD Sniffing

May 5, 2022 by 27 Comments

[Jure Spiler] was at a flea market and got himself a spectrophotometer — a device that measures absorbance and transmittance of light at different wavelengths. This particular model seems to be about 25 years old, and it’s controlled by a built-in keyboard and uses a graphical LCD to display collected data. That might have been acceptable when it was made, but it wasn’t enough for [Jure]. Since he wanted to plot the spectrophotometry data and be able to save it into a CSV file, hacking ensued.

He decided to tap into the the display communication lines. This 128×64 graphical display, PC-1206B, uses a 8-bit interface, so with a 16-channel logic analyzer, he could see the data being sent to the display. He even wrote decoder software – taking CSV files from the logic analyzer and using primitive optical recognition on the decoded pixels to determine the digits being shown, and drawing a nice wavelength to absorbance graph. From there, he set out to make a standalone device sniffing the data bus and creating a stream of data he could send to a computer for storage and processing.

[Jure] stumbled into a roadblock, however, when he tried to use an Arduino for this task. Even using a sped-up GPIO library (as opposed to notoriously inefficient digitalRead), he couldn’t get a readout frequency higher than 80 KHz – with the required IO readout rate deemed as 1 MHz, something else would be called for. We do wonder if something like RP2040 with its PIO machinery would be better for making such captures.

At that point, however, he found out that there’s undocumented serial output on one of the pins of the spectrophotometer’s expansion port, and is currently investigating that, having shelved the LCD sniffing direction. Nevertheless, this serves as yet another example for us, for those times when an LCD connection is all that we can make use of.

We’ve seen hackers sniff LCD interfaces to get data from reflow ovens, take screenshots from Game Boys and even equip them with HDMI and VGA ports afterwards. With a skill like this, you can even give a new life to a vintage calculator with a decayed display! Got an LCD-equipped device but unsure about which specific controller it uses? We’ve talked about that!

Continue reading “Exporting Data From Old Gear Through LCD Sniffing” →