USB LED Christmas Tree Is Making Spirits Bright

December 13, 2021 by Kristina Panos 9 Comments

[Piotr SB] knows there is no way out of the holidays; the only path is through. You’ve got to find cheer wherever and however you can, so why not cater to your own interests and build the cutest little LED Christmas tree you ever did see? And did we mention it’s USB and absolutely free (as in carols, not eggnog)?

This O-Christmas tree is made up of concentric rings that are built into a tier as you solder the LEDs. And of course you’re supposed use the LED legs as supports! One leg from each LED — 18 green and a red one for the top. Because the PCB is not quite thick enough, you’ll need to add a plastic spacer to get it to stay in the USB port. Not only is this a nice design, the snowflakes and snowman on the silkscreen totally seal the cuteness deal.

Ever get so frustrated with your Christmas tree that you want to just empty a few rounds into the thing? No? Well, you’d have a good reason to if you built this Duck Hunt ornament.

Ask Hackaday: Are Extruders The Only Feasible Tools For Toolchanging?

December 13, 2021 by Donald Papp 35 Comments

Toolchanging in 3D printers is no longer something from the bleeding edge; it’s going mainstream. E3D has a high-quality kit for a toolchanger and motion system, our own Joshua Vasquez has shared details about the open-source toolchanging Jubilee design, and just recently Prusa3D formally announced the Prusa XL, which promises toolchanging with up to five different extruders.

It’s safe to say toolchanging on 3D printers has stepped to the front, but what comes next? What kind of tools other than extruders make sense on a 3D printer?

First, let’s explain what makes separate extruders such fantastic tools. Being able to change extruders on-demand during a print enables things like true multi-material printing. Printing in more than one color or material will no longer be done by pushing different filaments through a single nozzle, which limits a print to materials that extrude under similar conditions and temperatures. Toolchanging means truly being able to print in multiple materials, even if they have different requirements, because each material has its own extruder. That’s a clear benefit, but what about tools other than extruders?

Continue reading “Ask Hackaday: Are Extruders The Only Feasible Tools For Toolchanging?” →

Design For Test Hack Chat

December 13, 2021 by Dan Maloney 3 Comments

Join us on Wednesday, December 15 at noon Pacific for the Design for Test Hack Chat with Duncan Lowder!

If your project is at the breadboard phase, or even if you’ve moved to a PCB prototype, it’s pretty easy to know if it works. It either does what it’s supposed to do, or it doesn’t, and a few informal tests will probably tell you all you need to know. But once you scale up to production, the testing picture becomes quite different. How do you know you’re not shipping out a problem? And how do you make sure your testing process doesn’t become a bottleneck?

Answering questions like these can be difficult, which is why we’ve invited Duncan Lowder to come talk with us. He was a test lead at places like Glowforge and Sphero before founding FixturFab, where he’s working on ways to make hardware testing as easy as possible, no matter what scale you’re working at. We’ll learn all about how to make our designs easy to test right from the get-go and take the pain out of that bed of nails.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, December 15 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

Adding Wire Races Improves 3D-Printed Bearings

December 13, 2021 by Dan Maloney 38 Comments

Like a lot of power transmission components, bearings have become far easier to source than they once were. It used to be hard to find exactly what you need, but now quality bearings are just a few clicks away. They’re not always cheap though, especially when you get to the larger sizes, so knowing how to print your own bearings can be a handy skill.

Of course, 3D-printed bearings aren’t going to work in every application, but [Eros Nicolau] has a plan for that. Rather than risk damage from frictional heating by running plastic or metal balls in a plastic race, he uses wire rings as wear surfaces. The first video below shows an early version of the bearing, where a pair of steel wire rings lines the 3D-printed inner and outer races. These worked OK, but suffered from occasional sticky spots and were a bit on the noisy side.

The second video shows version two, which uses the same wire-ring race arrangement but adds a printed ball cage to restrain the balls. This keeps things quieter and eliminates binding, making the bearing run smoother. [Eros] also added a bit of lube to the bearing, in the form of liquid PTFE, better known as Teflon. It certainly seemed to smooth things out. We’d imagine PTFE would be more compatible with most printed plastics than, say, petroleum-based greases, but we’d be keen to see how the bearings hold up in the long term.

Maybe you recall seeing big 3D-printed bearings around here before? You’d be right. And we’ve got you covered if you need to learn more about how bearings work — or lubricants, for that matter.

Continue reading “Adding Wire Races Improves 3D-Printed Bearings” →

Mining And Refining: From Red Dirt To Aluminum

December 13, 2021 by Dan Maloney 29 Comments

No matter how many syllables you use to say it, aluminum is one of the most useful industrial metals we have. Lightweight, strong, easily alloyed, highly conductive, and easy to machine, cast, and extrude, aluminum has found its way into virtually every industrial process and commercial product imaginable.

Modern life would be impossible without aluminum, and yet the silver metal has been in widespread use only for about the last 100 years. There was a time not all that long ago that aluminum dinnerware was a status symbol, and it was once literally worth more than its weight in gold. The reason behind its one-time rarity lies in the effort needed to extract the abundant element from the rocks that carry it, as well as the energy to do so. The forces that locked aluminum away from human use until recently have been overcome, and the chemistry and engineering needed to do that are worth looking into in our next installment of “Mining and Refining.”

Continue reading “Mining And Refining: From Red Dirt To Aluminum” →

New Pi Zero Gains Unapproved Antennas Yet Again

December 13, 2021 by Arya Voronova 25 Comments

We’ve only started to tap into the potential of the brand new Pi Zero 2. Having finally received his board, [Brian Dorey] shows us how to boost your Pi’s WiFi, the hacker way. Inline with the onboard WiFi antenna can be found a u.FL footprint, and you just know that someone had to add an external antenna. This is where [Brian] comes in, with a photo-rich writeup and video tutorial, embedded below, that will have you modify your own Zero in no time. His measurements show seeing fourteen networks available in a spot where he’d only see four before, and the RSSI levels reported have improved by 5 dB -10 dB, big when it comes to getting a further or more stable connection.

With old laptops being a decent source of WiFi antennas, you only need to procure a u.FL connector and practice soldering a bit before you take this on! The hardest part of such a project tends to be not accidentally putting any solder on the u.FL connector’s metal can – and [Brian] mostly succeeds in that! He shows how to disconnect the external antenna to avoid signal reflections and the like, and, of course, you will be expected to never power your Pi Zero on without an attached antenna afterwards, lest you have your transmitter become fatally confused by the mismatch of hardware-defined impedance expectations. A Pi Zero isn’t the only place where you’ll encounter footprints for connectors you can add, and arguably, that’s your duty as a hacker – modifying the things you work with in a way that adds functionality. Don’t forget to share how you did it!

This trick should be pretty helpful if you’re ever to put your new Pi Zero in a full-metal enclosure. Curious about the Raspberry Pi antenna’s inner workings? We’ve covered them before! If you’d like to see some previous Raspberry Pi mods, here’s one for the Pi 3, and here’s one for the original Zero W – from [Brian], too!
Continue reading “New Pi Zero Gains Unapproved Antennas Yet Again” →

Active Pickguard Makes For A Great Guitar Mod

December 13, 2021 by Lewin Day 6 Comments

Much discussion goes on in the guitar world about the best hardware to use. Whether its pickups, how they’re positioned, or even the specific breed of wood on the fretboard, it’s all up for debate. [Eli Hughes] put much of that to one side, however, with his innovative “Active Pickguard” project.

The project reimagines the electronics of an electric guitar from the ground up. Instead of typical electromagnetic pickups, six individual piezo pickups are built into the bridge – one for each individual string. The outputs of these pickups is conditioned and then read by the analog-to-digital converter of a Freescale Kinetis K40. The DSP-capable chip can then be used to apply all manner of effects. [Eli] demonstrates the guitar providing an uncanny imitation of an acoustic guitar, before demonstrating jazz and overdrive tones as well.

The Kinetis chip also features touch-sensitive inputs, which [Eli] put to good use. All the hardware is built into a pickguard-shaped PCB, complete with touch controls for things like volume, tone, and choosing different DSP patches.

Unlike a regular guitar, this one needs a power supply, which it gets via a CAT 6 cable, in place of the usual 1/4″ guitar cable. The CAT 6 also carries audio out to a converter box which allows the audio to be output to a regular guitar amplifier.

It’s a neat build, and one that shows just how modern technology can reimagine a simple 20th-century instrument. DSP really is magic, after all. Video after the break.

Continue reading “Active Pickguard Makes For A Great Guitar Mod” →