A Simple Touch Probe Made With Basic Tools

January 5, 2022 by 14 Comments
Six points of contact detect any displacement.

LinuxCNC contributor and machining enthusiast [Andy Pugh] is certainly not afraid to try making specialised tools to see how well they work out, and this time he’s been busy making a touch probe (video, embedded below) for checking the accuracy of machining operations and general measuring applications.

These things are not cheap, since they are essentially ‘just’ a switch with a long probe, But, as with anything specialised and machined with tight tolerances, you can understand why they cost what they do.

After inspecting and spending some time reverse-engineering such a unit, [Andy] then proceeded to grab some PEEK bar he had lying around and chuck it into the lathe (get it?). He notes Delrin would be more cost effective for those wishing to reproduce this, but as long as you have the ability to machine it and it’s non-conductive, there are many other options you could try.

Using no special tools other than a collet block (like this one) all the angled holes and slots were made with ease, with the help of a specially 3D-printed mount for the vise. A nice, simple approach, we think!

[Andy] tested the repeatability of the probe, mounted over his CNC-converted Holbrook lathe, reporting a value of 1 um, which seems rather good. Centering of the probe tip within the probe body was off a bit, as you’d expect for something made practically by hand, but that is less of a problem as it would seem, as it results in a fixed offset that can be compensated for in software. Perhaps the next version will have some adjustability to dial that out manually?

The whole assembly is formed from two plastic parts, a handful of ground-finished hardened steel pins, and a big spring. The only part remotely special is an off-the-shelf probe tip. During the electrical hookup, you may notice the use of a self-fluxing verowire pen, which was something this scribe didn’t know existed and has already placed an order for!

The reference 3D model for the design is shared from [Andy]’s Autodesk Drive for your viewing pleasure.

Of course, this isn’t the first DIY touch probe we’ve seen, here’s one for example, and over on Hackaday.IO, here’s an attempt to make one using a piezoelectric transducer.

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Ordering prototypes like they were fast food

Made To Spec: The Coming Age Of Prototyping As A Service

December 8, 2021 by 38 Comments

In the last decade, the price for making a single PCB plummeted. And we’ve featured tons of hacks with boards hailing from places like OSH Park or Seeed Studio. But this phenomenon isn’t isolated, and all sorts of one-off prototyping services are becoming cheaper and looking to satiate both hobbyist and engineer alike.

Today, I want to blow the lid off a few places offering one-off mechanical prototyping services. I’ll take us through some history of how we got here, introduce a few new players, and finally highlight some important tradeoffs before you start ordering bespoke aluminum parts straight to your doorstep.

Now go get your ANSI Z87+ safety glasses, and let’s get started.

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Axe Hacks: New Sounds For Your Electric Guitar Beginning From What Makes Them Tick

September 22, 2020 by 30 Comments

Creating music is a perfect hobby for anyone into hacking, and the amount of musical hacks and self-made instruments we come across here makes that supremely evident. It’s just a great match: you can either go full-on into engineering mode as music is in the end “just” applied physics, or simply ignore all of the theory and take an artistic approach by simply doing whatever feels right. The sweet spot is of course somewhere in between — a solid grasp of some music theory fundamentals won’t hurt, but too much overthinking eventually will.

The obvious choice to combine a favorite pastime like electronics or programming with creating music would be in the realm of electronic music, and as compelling as building synthesizers sounds, I’ll be going for the next best thing instead: the electric guitar. Despite its general popularity, the enormous potential that lies within the electric guitar is rarely fully utilized. Everyone seems to just focus on amp settings and effect pedals when looking for that special or unique sound, while the guitar itself is seen as this immutable object bestowed on us by the universe with all its predestined, magical characteristics. Toggle a pickup switch, and if we’re feeling extra perky, give that tone pot a little spin, that’s all there is to it.

The thing is, the guitar’s electrical setup — or wiring — in its stock form simply is as boring and generic as it can get. Sure, it’s a safe choice that does the job well enough, but there’s this entirely different world of tonal variety and individual controllability locked inside of it, and all it really takes is a screwdriver and soldering iron to release it. Plus, this might serve as an interesting application area to dive into simple analog electronics, so even if guitars aren’t your thing yet, maybe this will tickle your creativity bone. And if bass is more your thing, well, let me be ignorant and declare that a bass is just a longer guitar with thicker, lower-tuned strings, meaning everything that follows pretty much applies to bass as well, even if I talk about guitars.

However, in order to modify something, it helps to understand how it functions. So today, we’ll only focus on the basics of an electric guitar, i.e. what’s inside them and what defines and affects their tone. But don’t worry, once we have the fundamentals covered, we’ll be all settled to get to the juicy bits next time.

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Frances Allen Optimised Your Code Without You Even Knowing

August 25, 2020 by 9 Comments

In 2020, our digital world and the software we use to create it are a towering structure, built upon countless layers of abstraction and building blocks — just think about all the translations and interactions that occur from loading a webpage. Whilst abstraction is undoubtedly a great thing, it only works if we’re building on solid ground; if the lower levels are stable and fast. What does that mean in practice? It means low-level, compiled languages, which can be heavily optimised and leveraged to make the most of computer hardware. One of the giants in this area was Frances Allen, who recently passed away in early August. Described by IBM as “a pioneer in compiler organization and optimization algorithms,” she made numerous significant contributions to the field. Continue reading “Frances Allen Optimised Your Code Without You Even Knowing” →

DNA Now Stands For Data And Knowledge Accumulation

February 18, 2020 by 33 Comments

Technology frequently looks at nature to make improvements in efficiency, and we may be nearing a new breakthrough in copying how nature stores data. Maybe some day your thumb drive will be your actual thumb. The entire works of Shakespeare could be stored in an infinite number of monkeys. DNA could become a data storage mechanism! With all the sensationalism surrounding this frontier, it seems like a dose of reality is in order.

The Potential for Greatness

The human genome, with 3 billion base pairs can store up to 750MB of data. In reality every cell has two sets of chromosomes, so nearly every human cell has 1.5GB of data shoved inside. You could pack 165 billion cells into the volume of a microSD card, which equates to 165 exobytes, and that’s if you keep all the overhead of the rest of the cell and not just the DNA. That’s without any kind of optimizing for data storage, too.

This kind of data density is far beyond our current digital storage capabilities. Storing nearly infinite data onto extremely small cells could change everything. Beyond the volume, there’s also the promise of longevity and replication, maintaining a permanent record that can’t get lost and is easily transferred (like medical records), and even an element of subterfuge or data transportation, as well as the ability to design self-replicating machines whose purpose is to disseminate information broadly.

So, where is the state of the art in DNA data storage? There’s plenty of promise, but does it actually work?

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Hackaday Celebrates 15 Years And Oh How The Hardware Has Changed

September 5, 2019 by 56 Comments

Today marks exactly 15 years since Hackaday began featuring one Hack a Day, and we’ve haven’t missed a day since. Over 5,477 days we’ve published 34,057 articles, and the Hackaday community has logged 903,114 comments. It’s an amazing body of work from our writers and editors, a humbling level of involvement from our readers, and an absolutely incredible contribution to open hardware by the project creators who have shared details of their work and given us all something to talk about and to strive for.

What began as a blog is now a global virtual hackerspace. That first 105-word article has grown far beyond project features to include spectacular long-form original content. From our community of readers has grown Hackaday.io, launched in 2014 you’ll now find over 30,000 projects published by 350,000 members. The same year the Hackaday Prize was founded as a global engineering initiative seeking to promote open hardware, offering big prizes for big ideas (and the willingness to share them). Our virtual connections were also given the chance to come alive through the Hackaday Superconference, Hackaday Belgrade, numerous Hackaday Unconferences, and meetups all over the world.

All of this melts together into a huge support structure for anyone who wants to float an interesting idea with a proof of concept where “why” is the wrong question. Together we challenge the limits of what things are meant to do, and collectively we filter through the best ideas and hold them high as building blocks for the next iteration. The Hackaday community is the common link in the collective brain, a validation point for perpetuating great ideas of old, and cataloging the ones of new.

Perhaps the most impressive thing about the last 15 years of Hackaday is how much the technological landscape has changed. Hackaday is still around because all of us have actively changed along with it — always looking for that cutting edge where the clever misuse of something becomes the base for the next transformative change. So we thought we’d take a look back 15 years in tech. Let’s dig into a time when there were no modules for electronics, you couldn’t just whip up a plastic part in an afternoon, designing your own silicon was unheard of, and your parts distributor was the horde of broken electronics in your back room.

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Etching Large Brass Sheets Is Harder Than You Think

June 19, 2019 by 32 Comments

One of my favorite ways to think of engineering is that a glass is not half empty or half full, only twice as large as it needs to be. As useful as that idea is, it also means that I rarely put any effort into the aesthetics of my projects – I learn or accomplish what I need, desolder and recycle the components, then move on. Few of my projects are permanent, and custom cases tend to be non-reusable, so I skip the effort and expense.

Once in a while though, I need to make a gift. In that case form and function both become priorities. Thankfully, all that glitters is not gold – and over the last year I’ve been learning to etch the copper alloys commonly classified as ‘brass’. We’ve covered some truly excellent etched brass pieces previously, and I was inspired to try and etch larger pieces of metal (A4 and larger) without sacrificing resolution. I thought this would be just like etching circuits. In fact, I went through several months of failed attempts before I produced anything halfway decent!

Although I’m still working on perfecting my techniques, I’ve learned enough in the meantime to give a report. Read on if you’re feeling the need for more fancy brass signs in your life.

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