A pair of RP2040-based USB microphones

Mico Is A USB Microphone Based On A Pi Pico

December 25, 2021 by 20 Comments

When [Mahesh Venkitachalam] was experimenting with machine learning for audio applications on a Raspberry Pi, he found himself looking for a simple USB microphone. A cheap one was easy to find, but the sound quality and directionality left much to be desired. A large, studio-quality mic would be overkill, so [Mahesh] decided to simply build exactly what was needed: a compact, yet high-quality USB microphone that he called Mico.

The sensing device is a MEMS microphone that outputs a pulse density modulated (PDM) signal. There are chips available to directly interface such a microphone to a USB port, but [Mahesh] found them difficult to work with and therefore settled on something he knew already: the Raspberry Pi Pico platform. Luckily, someone had already figured out how to read out a microphone and present a USB device to a PC, so all that was needed was to put all the bits together into a convenient form factor.

The great thing about the Pico platform is that its main controller chip, the RP2040, is available as a separate component. [Mahesh] designed a sleek little PCB that holds the RP2040 along with the MEMS microphone and a USB connector. The end result looks tidy enough that it might have come out of a mass-produced gizmo. Those don’t usually come with full schematics and source code, but the Mico does: everything is available on its GitHub page for anyone to re-use and improve.

You can judge the sound quality for yourself in the video embedded below. If you like DIY USB microphones, you’re in luck: we’ve featured one based on an STM32 as well as a beautiful recreation of a studio-quality mic.

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3D Printing Gets Tiny

December 25, 2021 by 6 Comments

Using a process akin to electroplating, researchers at the University of Oldenburg have 3D printed structures at the 25 nanometer scale. A human hair, of course, is thousands of time thicker than that. The working medium was a copper salt and a very tiny nozzle. How tiny? As small as 1.6 nanometers. That’s big enough for two copper ions at once.

Tiny nozzles are prone to every 3D printer’s bane: clogged nozzles. To mitigate this, the team built a closed-loop control that measured electrical current between the work area and inside the nozzle. You can read the full paper online.

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Mini Linear Actuators From DVD Drive Parts

December 25, 2021 by 11 Comments

For many years now a source for some of the smallest and cheapest home made CNC mechanisms has been the seemingly never-ending supply of surplus CD and DVD-ROM drives. The linear actuator that moves the laser may not be the longest or the strongest, but it’s free, and we’ve seen plenty of little X-Y tables using CD drives. It’s these mechanisms that [Nemo404] has taken a little further, freeing the lead screw and motor from the drive chassis and placing them in a 3D-printed enclosure for a complete linear actuator that can be used in other projects. (Video, embedded below.)

There seems to be no positional feedback, not even the limit switch that would grace a typical CD drive, but aside from that it makes for a compact unit. There are two versions, one for a linear bearing and the other for the brass bushes found in CD drives. It’s unclear how strong the result is, but it appears to be strong enough to demonstrate lifting a small container of screws.

Should you need to make your own actuator then aside from the easy-to-obtain old CD drive the files can be found on Thingiverse. And introduce yourself to the world of CD drives for CNC machines by taking a look at this mill.

Thanks [BaldPower] for the tip!

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Blender? No, Grinder

December 25, 2021 by 12 Comments

[Leandro Felipe] is no stranger to the dirty hack, and this video of his conversion of a blender into a handheld rotary grinding tool is no exception. (Embedded below.) But the end result is something pretty useful — a lighter and more maneuverable rotary grinder that’s got a lot more grunt to boot.

(The video is in Portuguese, but the captions work pretty well, once you get over the fact that the robots translate “grinding tool” as “rectifier” a lot of the time. And anyway, you’re here for the hacks.)

The highlights are a handmade coupling that mates the blender motor with the flexible shaft and chuck, purchased separately. And the flattened-out PVC pipe used as a mounting bracket. And him using the motor itself against a file to “lathe” down the drive shaft. And…

The tip of the day comes when he holds the blender motor in a metal vise to test it out. Metal and spinning magnets — what’s the worst that could happen?  Sparks, smoke, and a trip to the thrift store for another used blender.

If you just want to see the finished piece, you can jump ahead to the end. But it’s basically, get yourself a speed-adjustable blender, couple it to the shaft of an off-the shelf grinder, and you’re set.

It’s an idea so conceptually easy, you might wonder if Hackaday has ever showcased a blender dr3mel before. We have. What else can you power with a blender motor?

Thanks [Danjovic] for the tip!

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3D Prints With A Mirror Finish

December 25, 2021 by 15 Comments

As anyone who has used a 3D printer before knows, what comes off the bed of your regular FSD printer is by no means a mirror finish. There are layers in the print simply by the nature of the technology itself, and the transitions between layers will never be smooth. In addition, printers can use different technology for depositing layers, making for thinner layers (SLA, for example). With those challenges in mind, [AlphaPhoenix] set out to create an authentic mirror finish on his 3D prints. (Video, embedded below.)

As the intro hints, mirrors need very flat/smooth surfaces to reflect light. To smooth his prints, [AlphaPhoenix] first did a light sanding pass and then applied very thick two-part epoxy, allowing surface tension to do the smoothing work for him. Once dried, silver was deposited onto the pieces via a few different sprays. First, a wetting agent is applied, which prevents subsequent solutions from beading up. Next, he sprays the two precursors, and they react together to deposit elemental silver onto the object’s surface. [AlphaPhoenix] asserts that he isn’t a chemist and then explains some of the many chemical reactions behind the process and theorizes why the solutions break down a while after being mixed.

He had an excellent first batch, and then subsequent batches came out splotchy and decided un-mirror-like. As we mentioned earlier, the first step was a wetting agent, which tended to react with the epoxy that He applied. Then, using a grid search with four variables, [AlphaPhoenix] trudged through the different configurations, landing on critical takeaways. For example, the curing time for the epoxy was essential and the ratio between the two precursor solutions.

Recently we covered a 3D printed mirror array that concealed a hidden message. Perhaps a future version of that could have the mirror integrated into the print itself using the techniques from [AlphaPhoenix]?

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Do You Need A Cycloidal Drive?

December 25, 2021 by 10 Comments

A cycloidal gear drive is one of the most mesmerizing reduction gears to watch when it is running, but it’s not all just eye-candy. Cycloidals give decent gearing, are relatively compact and back-drivable, and have low backlash and high efficiency. You probably want one in the shoulder of your robot arm, for instance.

But designing and building one isn’t exactly straightforward. Thanks, then, to [How To Mechatronics] for the lovely explanation of how it works in detail, and a nice walkthrough of designing and building a cycloidal gear reducer out of 3D printed parts and a ton of bearings. If you just want to watch it go, check out the video embedded below.

The video is partly an ad for SolidWorks, and spends a lot of time on the mechanics of designing the parts for 3D printing using that software. Still, if you’re using any other graphical CAD tool, you should be able to translate what you learned.

It’s amazing that 3D printing has made sophisticated gearbox designs like this possible to fabricate at home. This stuff used to be confined to the high-end machine shops of fancy robotics firms, and now you can make one yourself this weekend. Not exotic or unreliable enough for you? Well, then, buy yourself some flexible filament and step on up to the strain wave, aka “harmonic drive”, gearbox.

Thanks to serial tipster [Keith] for the tip!

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Hacking Film Processing With Coffee

December 24, 2021 by 31 Comments

Years ago, doing your own darkroom work was the only way to really control what your pictures looked like. In those days, coffee was what kept you going while you mixed another batch of noxious chemicals in the dark and fumbled to load a tank reel by feel. But did you know that you can process black and white film with coffee? Not just coffee, of course. [Andrew Shepherd] takes us through the process using what is coyly known as Caffenol-C.

Apparently, the process is not original, but if you’ve ever wanted to do some film developing and don’t want exotic and dangerous chemicals, it might be just the ticket. The ingredients are simple: instant coffee, washing soda, water and –optionally — vitamin C powder. If nothing else, all of this is safe to pour down your drain, something you probably aren’t supposed to do with conventional developers that contain things like formaldehyde and methyl chloroform.

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