How To Solder To Aluminum, Easily

March 6, 2022 by 53 Comments

[Ted Yapo] shared a method of easily and conveniently soldering to aluminum, which depends on a little prep work to end up only slightly more complex than soldering to copper. A typical way to make a reliable electrical connection to aluminum is to use a screw and a wire, but [Ted] shows that it can also be done with the help of an abrasive and mineral oil.

Aluminum doesn’t solder well, and that’s because of the oxide layer that rapidly forms on the surface. [Ted]’s solution is to scour the aluminum with some mineral oil. The goal is to scrape away the oxide layer on the aluminum’s surface, while the mineral oil’s coating action prevents a new oxide layer from immediately re-forming.

After this prep, [Ted] uses a hot soldering iron and a blob of solder, heating it until it sticks. A fair bit of heat is usually needed, because aluminum is a great heat conductor and tends to be lot thicker than a typical copper ground plane. But once the aluminum is successfully tinned, just about anything can be soldered to it in a familiar way.

[Ted] does caution that mineral oil can ignite around 260 °C (500 °F), so a plan should be in place when using this method, just in case the small amount of oil catches fire.

This looks like a simple technique worth remembering, and it seems easier than soldering by chemically depositing copper onto aluminum.

DIY Injection Molder Built From A Cheap Pneumatic Press

March 6, 2022 by 10 Comments

[Kurt Schaefer] was watching YouTube videos of people making molds for injection molding purposes using what he considered to be the toy 3018 CNC machines, and looking at the results, decided he needed a piece of the action. However, once you have molds, the next obvious issue to address is lack of access to an injection molding machine. But these things are expensive. As luck would have it, you can get a nice-looking pneumatic press for less than $350, and with a little more money spent, [Kurt] found he could convert it into a functional injection molding machine (video, embedded below), and get some half-decent results out of it.

After ordering the press on eBay, what eventually arrived was quite a mess, having clearly been inadequately packed for its weight, and had sustained some damage in transit. Despite this, it seemed the functional bits were fine, so [Kurt] decided to press on with the build. The first obvious change is the requirement of a heated chamber to deal with the feedstock material. Using an off-the-shelf injection molding chamber by buster beagle 3D, only a few standoffs and a support bracket needed machining in order to complete the mechanics. A common PID controller available from the usual suppliers, with some heat bands wrapped around the chamber, dealt with the injection temperature requirements, and some 3D printed enclosures wrapped it all up neatly.

After some initial wobbles, and a couple of hacks to the design, [Kurt] got some pretty good results out of this simple setup, and it appears to be pretty tune-able and repeatable, which will help maintain the quality of those results. In short, a neat hack of easy to get parts, and perhaps a welcome addition to a hackerspace near you?

3D printed parts are available on the Thingiverse page, as well as a Fusion360 CAD model. The shopping list for parts can be found in the video description, if you want to have a go at reproducing this.

We’ve seen a few DIY injection molding attempts over the years, like this slick plastic molding setup. Here’s one with 3D-printed molds, and if you just need something the right shape, you could just injection mold with a hot glue.

Continue reading “DIY Injection Molder Built From A Cheap Pneumatic Press” →

Robotic Tufting Gun Fires Off CNC Textiles

March 5, 2022 by 6 Comments

Often used to make rugs, tufting is a process wherein a hollow needle is used to cram thread or yarn into fabric in some kind of pattern. This can be done by hand, with a gun, or with big machines. Some machines are set up to punch the same pattern quickly over and over again, and these are difficult to retool for a new pattern. Others are made to poke arbitrary patterns and change easily, but these machines move more slowly.

This robotic tufting system by [Owen Trueblood] is of the slow and arbitrary type. It will consist of a modified tufting gun strapped to a robot arm for CNC textile art. Tufting guns are manufactured with simple controls — a power switch, a knob to set the speed, and a trigger button to do the tufting. Once it’s affixed to the robot arm, [Owen] wants to remote control the thing.

The gun’s motor driver is nothing fancy, just a 555 using PWM to control a half H-bridge based on input from the speed control potentiometer. [Owen] replaced the motor controller with an Arduino and added an I/O port. The latter is a 3.5 mm stereo audio jack wired to GND and two of the Arduino’s pins. One is a digital input to power the gun, and the other is used as an analog speed controller based on input voltage. [Owen] is just getting started, and we’re excited to keep tabs on this project as the gun goes robotic.

This isn’t the first time we’ve seen robots do textiles — here’s a 6-axis robot arm that weaves carbon fiber.

Minecraft furnace IRL

Replica Minecraft Furnace Actually Powers The Game

March 5, 2022 by 3 Comments

Let’s face it, we all need a little distraction sometimes, especially lately. And for our money, there’s no better way to put your brain in park than to start up a Minecraft world and get to digging. The simple graphics, the open world, and the lack of agenda other than to find resources and build things are all very soothing.

But play the game long enough and you’re bound to think about what it would be like if the game world crossed over into the real world. The ironically named [Michael Pick] did just that when he managed to craft a real Minecraft furnace that can actually power the game. Of course, there are some liberties taken with the in-game crafting recipe for a furnace, which is understandable for a game that allows you to punch trees with a bare fist to cut them down.

Rather than using eight blocks of cobblestone to build his furnace, [Michael] made a wooden shell for a commercial folding camp stove. Insulated from the shell by a little cement board, the furnace looks pretty true to the in-game item. To generate the electricity needed to run the game, he used a pair of thermoelectric camping generators. With the stove filled with wood — presumably un-punched — the generators put out enough juice to at least partially charge a battery bank, which was then used to power a Raspberry Pi and 7″ monitor. His goal was to get enough power from the furnace to do a speed run in the game and find three diamonds to build a diamond pickaxe. Honestly, we’re jealous — our first diamonds never come that easy.

We’ve seen other Minecraft-IRL crossovers before. Fancy a ride in a minecart? We’ve got that covered. Or maybe you’d rather control a desk lamp from within the game? That’s a thing, too.

Continue reading “Replica Minecraft Furnace Actually Powers The Game” →

One Stepper Plus A Whole Bunch Of Magnets Equals A Unique Seven-Segment Display

March 5, 2022 by 24 Comments

Sometimes the cost of simplicity is extra complexity. It seems counterintuitive, but it seems to be true. And this single-motor mechanical seven-segment display seems to be a perfect example of this paradox.

On second thought, [aeropic]’s mechanism isn’t really all that mechanically complicated, but there sure was a lot of planning and ingenuity that went into it. The front has a 3D-printed bezel with the familiar segment cutouts, each of which is fitted with a pivoting segment, black on one side and white on the other.

Behind the bezel is a vertical shaft with three wheels, one behind each horizontal segment, and a pair of horizontal shafts, each with two wheels behind each vertical segment. The three shafts are geared to turn together by a single stepper in the base. Each wheel has ten magnets embedded in the outer circumference, with the polarity oriented to flip the segment in front of it to the right orientation for the current digit. It’s probably something that’s most easily understood by watching the video below.

We’ve seen quite a few of these mechanical seven-segment displays lately — this cam-and-servo mechanism comes to mind. We love them all, of course, but the great thing about [aeropic]’s display is how quiet it is — the stepper is mostly silent, and the segments make only a gentle clunk when they flip. It’s very satisfying.

Continue reading “One Stepper Plus A Whole Bunch Of Magnets Equals A Unique Seven-Segment Display” →

Miniature Motorized RC Car Is Massively Impressive

March 5, 2022 by 32 Comments

Small is often subjective. For example, a school bus is small compared to an Airbus A380. But other things are just small all on their own and need no comparison to make the point. Such is the case with this micro RC car in the video below the break. It’s an RC model of the Smart Car, that when compared to other vehicles on the road, is quite diminutive, both subjectively and absolutely. But the outward appearance of [diorama111]’s project only tells half the story.

Starting out as a static display model, [diorama111] fully disassembled the 1/87 scale Smart Car and got to work. Fully proportional steering is attained with a very, very small stepper motor that drives custom knuckles attached to handmade suspension. They are works of art in their own right.

Do your projects need tweezers for assembly?

Drive is supplied by another small stepper motor. If [diorama111] had stopped there, it would have been every bit as noteworthy to see a 1/87 Smart Car doing figure eights around small bottles of model paint. Instead, [diorama111] kept going! The car has working turn signals, brake lights (including the 3rd taillight in the back window!) and headlights. There is even a function for hazard lights.

The electronics are all hand built using enameled wire and SMD components on perf board, and are a study in miniaturization all their own. An ATtiny processor seems right at home in this design. We admire [diorama111]s steady hands and patience to build such a small RC car, never mind one with such fine attention paid to all the details.

If downsized hacks like this float your thimble-sized boat, you might also appreciate this precious little PDP-11 and terminal.

Continue reading “Miniature Motorized RC Car Is Massively Impressive” →

Low-Cost, Two-Channel Scriptable Waveform Generator

March 5, 2022 by 14 Comments

Microcontroller addict [Debraj] decided to make his own programmable sine wave generator, and was able to put it together for under $40 USD. Other than low-cost, his list of requirements was as follows:

  • Dual sine wave output, synchronized
  • Frequency, Amplitude, and Phase control
  • Low harmonics under 1 MHz
  • Scriptable via Python

The heart of the project is the Analog Devices AD9833, a complete Direct Digital Synthesis (DDS) waveform generator system on a chip. If you’ve ever rolled your own DDS using discrete ICs or in an FPGA, you can appreciate the benefit of squeezing the phase accumulator, sine lookup table, DAC, and control logic all into a single ten-pin package. [Debraj] uses AD9833 modules from the usual online vendors for a few dollars each. He synchronizes the generators by disconnecting the reference crystal on the second module and driving it from the first one. The remaining specifications are met by the inherent characteristics of the DDS system, and the scriptable interface is accomplished with an Arduino controlling the AD9833 chips and two programmable gain amplifiers (MCP6S31). We like the confidence that [Debraj] displays by sketching the initial circuit diagram with a ball-point pen — check out the sketch and the final pictorial schematic in the video below the break.

This is a good example of combining off-the-shelf modules to quickly build a project. This approach is great for one-off builds or as a proof-of-concept test bed that can later be spun onto a custom PCB. Another reason to use modules these days is that the modules are often in-stock but the chips are unobtainable. Though it appears [Debraj]’s only needs one of these generators, it would be an easy board to layout and build — if you can buy the parts.

Continue reading “Low-Cost, Two-Channel Scriptable Waveform Generator” →