3D Printering: Corrugated Plastic For Cheaper & Easier Enclosures

October 6, 2021 by Donald Papp 37 Comments

Clear acrylic panels have long been a mainstay of 3D printer enclosure designs, but they can also add significant cost in terms of money, shipping, weight, and hassle. An alternative material worth looking at is corrugated plastic (also known by its trade name coroplast) which is cheap, light, an excellent insulator, and easy to work with. Many enclosure designs can be refitted to use it instead of acrylic, so let’s take a closer look at what it has to offer.

What’s Wrong With Acrylic?

It’s not just the purchase price that makes acrylic a spendy option. Acrylic is fairly heavy, and shipping pieces the size of enclosure panels can be expensive. Also, cutting acrylic without special tools can be a challenge because it cracks easily if mishandled. Acrylic cuts beautifully in a laser cutter, but most laser cutters accessible to a hobbyist are not big enough to make enclosure-sized panels. If you are stuck with needing to cut acrylic by hand, here are some tips on how to get by with the tools you have.

It is best to source acrylic from a local shop that can also cut it to size with the right tools for a reasonable price, but it is still far from being a cheap material. There’s another option: corrugated plastic has quite a few properties that make it worth considering, especially for a hobbyist.

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Building A Multi-Ton Power Loader For Fun

October 6, 2021 by Danie Conradie 18 Comments

Exoskeletons, power suits, and iron suits in science fiction have served as the inspiration for many engineers and engineering projects over the years. This is certainly the case at [Hacksmith Industries], where Hackaday alum [James Hobson] has been building a massive mechanical exoskeleton since January 2019, inspired by the P-5000 Power Loader from the Alien movies. (Video, embedded below.)

Unlike the movie version, the [Hacksmith] power loader is not bipedal but built on top of the chassis of a small tracked skid-steer loader. Its existing hydraulic power unit also feeds all the upper body hydraulic cylinders. The upper body maintains the basic look of the movie version and was built from plasma-cut steel sections that fit together with a tab and slot system before being welded. Each arm has five degrees of freedom, controlled by proportional hydraulic valves. The power loader is controlled by an industrial grade control system based on the Raspberry Pi, running ROS.

Every single actuator is capable of applying enough force to kill, so safety is an important consideration in the design. It has emergency stop buttons mounted in several locations, including on a wireless remote. The ROS controller monitors the position of every cylinder using string potentiometers for closed-loop control, and to trigger the emergency stop if an actuator goes out of bounds. The power loader can be controlled by the onboard pilot using a pair of simulator flight controller joysticks, or remotely using a PS4 controller.

[Hacksmith Industries] is clear about the fact that they are building multi-ton power loaded for fun and entertainment, not because it’s necessarily practical or a commercially viable product. However, other exoskeletons have proven that they are a viable solution for reducing fatigue and risk of injury for industrial workers, and carrying heavy loads in rough terrain.

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An Atari ST running a campground reservation system

Atari ST Still Manages Campground Reservations After 36 Years

October 6, 2021 by Robin Kearey 40 Comments

“Don’t fix it if it ain’t broke”. That’s what we guess [Frans Bos] has been thinking for the past few decades, as he kept using his Atari ST to run a booking system for the family campground. (Video, embedded below.)

Although its case has yellowed a bit, the trusty old machine is still running 24/7 from April to October, as it has done every year since 1985. In the video [Frans] demonstrates the computer and its custom campground booking system to [Victor Bart].

To be exact, we’re looking at an Atari 1040STF, which runs on a 68000 CPU and has one full megabyte of RAM: in fact it was one of the first affordable machines with that much memory. Output is through a monochrome display, which is tiny compared to the modern TFT standing next to it, but was apparently much better than the monitor included with a typical DOS machine back in the day.

Since no campground management software was available when he bought the computer, [Frans] wrote his own, complete with a graphical map showing the location of each campsite. Reservations can be made, modified and printed with just a few keystrokes. The only concession to the modern world is the addition of a USB drive; we can imagine it was becoming difficult to store and exchange data using floppy disks in 2021.

We love seeing ancient hardware being actively used in the modern world: whether it’s floppy disks inside a Boeing 747 or an Amiga running a school’s HVAC system. Thanks to [Tinkerer] for the tip.

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BreadBin Is An 8-bit TTL CPU On A Breadboard, In A Bread Bin

October 5, 2021 by Robin Kearey 11 Comments

Building a CPU out of logic gates is a great way to learn about the inner workings of microprocessors, and we’ve seen several impressive projects in this area. [c0pperdragon] set himself the task of designing a very capable 8-bit CPU using just 74HC type logic chips on a large plug-in breadboard. To emphasize the “bread” theme, he put the whole thing inside an actual bread bin and named the accompanying software BERND after an anthropomorphic loaf from a German TV channel.

Getting a reliable breadboard big enough for the task at hand required some engineering by itself: cheap breadboards often have trouble making a reliable contact at each and every pin, while the length of the ground path and lack of shielding cause trouble for high-speed circuits. [c0pperdragon] therefore bought high-quality breadboards and soldered the ground wires together to get a proper low-resistance path. A ground plane made of aluminium foil should also help to prevent signal integrity issues.

The total circuit is incredibly compact for a complete CPU, using just 33 chips. This includes 64 KB of flash to store programs as well as a 555 timer to generate a clock signal. I/Os are limited to simple eight-bit input and output buses, but a sixteen-bit address bus gives it plenty of space to add ROM, RAM or fancier interfaces.

The aforementioned BERND program is an emulator that allows the BreadBin to run code written for the 65C816 processor, the 16-bit CPU used in the Super Nintendo and the Apple IIGS. This makes it easy to re-use programs developed for [c0pperdragon]’s earlier OS816 system, which uses an actual 65C816 chip.

This has to be one of the cleanest breadboard CPU designs we’ve seen so far, certainly a lot cleaner than this one. If you’d like to watch a detailed guide to building an 8-bit CPU on a breadboard, we recommend this project.

Repairing Underground Power Cables

October 5, 2021 by Al Williams 15 Comments

When we were kids, overhead power cables were a constant fixture in the neighborhood. Not only were they the bane of our kites, but they also had a tendency to fail during storms leaving us in the dark. These days lots of cables go underground — safer for kites and harder to storm damage. On the other hand, if they do need repair, it is a major operation, as [Practical Engineering] discusses in a recent post you can watch below.

In the story, a large underground distribution cable — the Scattergood-Olympic transmission line — had a failure in the late 1980s. The 10 mile line has three high-voltage phases and when the line was created, running high voltage lines underground was a bit exotic.

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Mini Camera Crane For Your Workbench

October 5, 2021 by Danie Conradie 10 Comments

If you’ve ever tried to document a project on your workbench with photos or videos, you know the challenge of constantly moving tripods to get the right shot. [Mechanistic] is familiar with this frustration, so he built a small desktop camera crane.

Heavily inspired by [Ivan Miranda]’s large camera crane, this build scales it down and mainly uses 3D printed parts. The arm of the crane can pivot along two axes around the base, uses a parallel bar mechanism to keep the camera orientation constant through its vertical range of motion. The camera mount itself allows an additional 3 degrees of freedom to capture any angle and can mount a DSLR or smartphone. To offset the weight of the camera, an adjustable counterweight is added to the rear of the arm. Every axis of rotation can be locked using thumbscrews.

We can certainly see a crane like this being useful on our workbench for more than just camera work. You could create attachments for holding lights, displays, multimeters, or some helping hands. For some tips on creating an engaging project video check out [Lewin Day]’s excellent video on the subject.

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Investigating A Defective USB Power Bank Module

October 5, 2021 by Tom Nardi 25 Comments

Call us old fashioned, but we feel like when you buy a piece of hardware, the thing should actually function. Now don’t get us wrong, like most of you, we’re willing to put up with the occasional dud so long as the price is right. But when something you just bought is so screwed up internally that there’s no chance it ever could have ever worked in the first place, that’s a very different story.

Unfortunately, that’s exactly what [Majenko] discovered when he tried out one of the USB-C power bank modules he recently ordered. The seemed to charge the battery well enough, but when he plugged a device into the USB output, he got nothing. We don’t mean just a low voltage either, probing with his meter, he became increasingly convinced that the 5 V pin on the module’s IP5306 chip literally wasn’t connected to anything.

Curious to know what had gone wrong, he removed all the components from the board and started sanding off the solder mask. With the copper exposed, his suspicions were confirmed. While they did route a trace from the chip to the via that would take the 5 V output the other side of the board, it wasn’t actually connected.

This is a pretty blatant bug to get left in the board, but to be fair, something similar has happened at least once or twice to pretty much everyone who’s ever designed their own PCB. Then again, those people didn’t leave said flaw in a commercially released module…

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