Wire EDM

Bringing The Power Of EDM To The Home Shop

January 20, 2022 by 17 Comments

When you see something made from metal that seems like it would be impossible to manufacture, chances are good it was made with some variety of electrical discharge machining. EDM is the method of choice for hard-to-machine metals, high aspect ratio hole drilling, and precise surface finishes that let mating parts slip together with almost zero clearance. The trouble is, EDM is a bit fussy, and as a result hasn’t made many inroads to the home shop.

[Action BOX] aims to change that with a DIY wire EDM machine. In wire EDM, a fine brass wire is used as an electrode to slowly erode metal in a dielectric bath. The wire is consumable, and has to constantly move from a supply spool through the workpiece and onto a takeup spool. Most of the build shown in the video below is concerned with the wire-handling mechanism, which is prototyped from 3D-printed parts and a heck of a lot of rollers and bearings. Maintaining the proper tension on the wire is critical, so a servo-controlled brake is fitted to the drivetrain, which itself is powered by a closed-loop stepper. Tension is measured by a pair of strain gauges and Arduinos, which control the position of the shaft brake servo and the speed of the motor on the takeup spool.

Unfortunately, in testing this setup proved to live up to EDM’s fussy reputation. The brass wire kept breaking as soon as cutting started, and [Action BOX] never made any actual cuts. There’s certainly promise, though, and we’re looking forward to developments. For more on EDM theory, check out [Ben Krasnow]’s look at EDM hole-drilling.

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Setup Menu Uses Text Editor Hack

January 20, 2022 by 19 Comments

Many embedded devices that require a setup menu will use a USB serial port which you connect to your favorite terminal emulator. But we recently encountered a generic USB knob that did setup using a text editor, like Notepad or even Vim (although that was a bit ugly). A company called iWit makes several kinds of USB knobs which end up in many such products.

These generic USB knobs are normally just plug-and-play, and are used to control your PC’s volume and muting. Some models, like the iWit, the user can configure the mapping within the device. For example, knob rotation can be set to generate up and down arrow keys, and knob press could be ENTER. One could do this kind of mapping on the PC, but many of these USB knobs can do it for you. The crux of the setup is this menu (which you can see in action in the first 30 seconds of the video below).

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Remoticon 2021 // Debra Ansell Connects PCB In Ways You Didn’t Expect

January 20, 2022 by 21 Comments

“LEDs improve everything.” Words to live by. Most everything that Debra Ansell of [GeekMomProjects] makes is bright, bold, and blinky. But if you’re looking for a simple string of WS2812s, you’re barking up the wrong tree. In the last few years, Debra has been making larger and more complicated assemblies, and that has meant diving into the mechanical design of modular PCBs. In the process Debra has come up with some great techniques that you’ll be able to use in your own builds, which she shared with us in a presentation during the 2021 Hackaday Remoticon.

She starts off with a quick overview of the state of play in PCB art, specifically of the style that she’s into these days: three dimensional constructions where the physical PCB itself is a sculptural element of the project. She’s crossing that with the popular triangle-style wall hanging sculpture, and her own fascination with “inner glow” — side-illuminated acrylic diffusers. Then she starts taking us down the path of creating her own wall art in detail, and this is where you need to listen up. Continue reading “Remoticon 2021 // Debra Ansell Connects PCB In Ways You Didn’t Expect” →

Congratulations Winners Of The 555 Timer Contest!

January 20, 2022 by 25 Comments

Sometimes the best inspiration is limitation. The 555 timer does “one thing” — compares a voltage to a couple thresholds and outputs a signal accordingly. It’s two comparators, a voltage ladder, and a flip-flop. And yet, it’s the most sold single chip of all time, celebrating its 50th birthday this year! So when Hackaday runs a 555 Timer Contest, hackers of all stripes come out with their best work to show their love for the Little DIP That Could.

The Winners

Far and away the favorite entry was the Giant 555 Timer by [Rudraksha Vegad]. Every one of our judges rated it in the top five, and it took top honors twice. On its face, this is a simple “giant 555 in a box” build, but have a look under the hood. Each sub-module that makes up the 555 — comparators, flip-flop, and amplifier — are made from salvaged discrete parts in actual breadboard fashion, soldered to brass nails hammered into wood. As an end product, it’s a nice piece of woodworking, but as a process of creation, it’s a masterwork in understanding the 555 at its deepest level. We should all make one!

The Menorah555 is a simple design with some very nice tricks up its sleeve. Perhaps the cutest of which is pulling the central candle out and lighting the others with it — a trick that involves a supercapacitor and reed switches. Each of the candle lighting circuits, however, use a 555 timer both for its intended purpose of providing a timed power-on reset pulse, and another 555 is used as a simple flip-flop. It’s a slick design, and a great user interaction.

The Cyclotone Mechanical Punk Console Sequencer is a rotating tower of circuit sculpture and noisemakers. This one looks great, is amazingly well documented in the video series, and uses a billion clever little tricks along the way. The 555’s role? Each of the four levels is the classic Atari Punk Console circuit.

All three of these projects win a $150 shopping spree at Digi-Key. That’s a lot of timers!

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Unpicking The Hype Around Web 3, What’s The Tech?

January 20, 2022 by 99 Comments

The buzzword of the moment in the frothier portions of the technology press is inescapable: “Web 3”. This is a collective word for a new generation of decentralised online applications using blockchain technologies, and it follows on from a similar excitement in the mid-2000s surrounding so-called “Web 2” websites that broke away from the static pages of the early Internet.

It’s very evident reading up on Web 3, that there is a huge quantity of hype involved in talking about this Next Big Thing. If this were April 1st it would be tempting to pen a lengthy piece sending up the coverage, but here in January that just won’t do. Instead it’s time to peer under the hype and attempt to discern what Web 3 really is from a technology standpoint. Sure, a Web 3 application uses blockchain technology, often reported breathlessly as “the Blockchain” as though there were only one, but how? What is the real technology beneath it all?

Where Did All This Web 3 Stuff Come From Anyway?

"This machine is a server. DO NOT POWER IT DOWN!!" Tim Berners-Lee's famous sticker on the front of his NeXTcube, the first web server.
“This machine is a server. DO NOT POWER IT DOWN!!” Tim Berners-Lee’s famous sticker on the front of his NeXTcube, the first web server. Binary Koala CC BY-SA 2.0.

In its earliest days, the web could be found only in academia, from Tim Berners-Lee at CERN, and then from others such as the National Center For Supercomputing Applications at the University of Illinois. In the mid-1990s the vast majority of web sites were served by the NCSA’s HTTPD server software, which served as the basis for the later hugely popular Apache project. Sites from this era were later dubbed Web 1.0, and operated as static HTML pages which could be refreshed only by reloading a page.

The millennium brought us Web 2.0. This is generally taken to refer to a much slicker generation of sites that made use of user-generated content. Behind every such generational shift lies a fresh technology, and if it was the HTTP server for Web 1.0, it was the use of Javascript in the browser to refresh page content on the fly for Web 2.0. This was dubbed AJAX, for Asynchronous Javascript And XML, and though the data transfer is now much more likely to be JSON than XML it remains the way that today’s web sites blur the line between a web page and an app. Continue reading “Unpicking The Hype Around Web 3, What’s The Tech?” →

The 3x0 in it's glory

Printing Your Own Exoskeleton

January 20, 2022 by 23 Comments

While not quite in a cave, the idea of making your own exoskeleton with limited tools does have a Tony Stark esque vibe. [Andrew Piccinno] is a mechanical engineer pursuing the dream of 3D printing a full-body exoskeleton called 3X0. It’s a project he’s been ruminating on since college, but the work really began in earnest about five months ago. Unfortunately, there are too many pictures to include here, but check out his Instagram or makeprojects for more photos.

To make sure parts fit, [Andrew] started with creating a mesh of his body. After running fifty pictures of himself holding relatively still through some photogrammetry software, he had a decent mesh. While measurements weren’t millimeter-accurate, the relative sizes of everything were reasonably accurate. While the design is modeled with his measurements in mind, all the different pieces are parametric, which in theory would allow someone to tweak the designs to fit their own body.

So far, all the parts have been entirely 3D printed, except for steel balls bearings, gas pistons, and tension bands. The non-3D printed parts are picked to be easy to obtain as the gas piston is just 100 N furniture pistons. The design process includes quite a bit of math, motion study, and simulation to make sure the part that he’s printing will not only fit but move correctly. Many parts, such as the shoulder, are built around a large custom bearing that allows the piece to move correctly with the user’s joints.

While still in the middle of development, [Andrew] has made some serious progress, and we’re looking forward to seeing it completed. The current design is primarily passive with just a few springs and pistons, but he is already looking forward to making it active to the degree that it can augment a user’s motions rather than just taking the load off. It’s clear that [Andrew] believes that exoskeletons are a look into a potential future, and we couldn’t agree more. In a similar vein, perhaps the techniques used in this powered exoskeleton arm on a budget could be used to power the 3X0?

When A Single Bit Was Enough, Into The Sound Of The ZX Spectrum

January 20, 2022 by 8 Comments

It’s normal for a computer in 2022 to come with a fully-featured sound card containing a complete synthesizer as well as high-quality PCM sound recording and playback. It’s referred to as a sound card after the way the hardware first appeared in the world of PCs, but in fact it’s now considered so essential as to be a built-in part of most mainboards. There was a time when computers boasted considerably less impressive sound hardware, and among the chorus of SIDs and AY chips of the perhaps the least well-featured was the original Sinclair ZX Spectrum. Its one-bit sound, a single line on an I/O port, is the subject of a thorough investigation from [Forgotten Computer]. It’s a long video which we’ve placed below the break, but for those with an interest in 8-bit music it should make a for a fascinating watch.

For Sir Clive Sinclair the 1-bit audio must have been welcome as it removed the need for an expensive sound chip and kept the Spectrum to its low price point, but on the face of it there was little more it could do than create simple beeps using Sinclair BASIC’s built-in BEEP command. The video gives us an in-depth look at how interleaving and PWM could be used to create much more complex sounds such as the illusion of multiple voices and even sampled sounds. In particular his technique of comparing the audio output with its corresponding pin on the Sinclair ULA shows the effect of the machine’s simple low-pass filter, though the music was often so close to the edge of what the interface could do that aliasing sounds are often very obvious.

As he demonstrates the various ingenious techniques that game and demo developers used to extract performance from such limited hardware that could even try to compete with the more sophisticated machines even at the same time as their code was running whatever was on the screen, it’s difficult not to come away with immense respect for their skills. If you’ve ever experimented with computer audio then you should try hardware this simple for yourself.

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