CeraMetal Lets You Print Metal, Cheaply And Easily

July 21, 2024 by 27 Comments

3D printing metal has been somewhat of a holy grail for the last decade in the hobby 3DP scene. We’ve seen a number of solutions, including using expensive filaments that incorporate metal into the usual plastic. In parallel, we’ve seen ceramic printers, and paste printers in general, coming into their own. What if you combined the two?

You’d get [Leah Buechly] et al’s CeraMetal process, which is the cheapest and most straightforward metal printing method we’ve seen to date. It all starts off with a custom bronze metal clay, made up of 100 g bronze powder, 0.17 g methyl cellulose, 0.33 g xanthan gum, and 9 g water. The water is fine-tuned to get the right consistency, and then it’s extruded and sintered.

The printer in question is an off-the-shelf ceramic printer that appears to use a pressurized clay feed into an auger, and prints on a linen bed. [Leah] had to write a custom slicer firmware that essentially runs in vase mode but incorporates infill as well, because the stop-start of normal slicers wreaked havoc with clay printing.

The part is then buried in activated carbon for support, and fired in a kiln. The result is a 3D printed bronze part on the cheap; the material cost is essentially just the cost of the metal powder and your effort.

We had never heard of metal clay before, but apparently jewelers have been using it for metals other than just bronze. The Metal Clay Academy, from the references section of the paper, is an amazing resource if you want to recreate this at home.

Paste printers are sounding more and more interesting. Obvious applications include printing chocolate and printing pancakes, but now that we’re talking metal parts with reasonably consistent shrinkage, they’ve got our attention.

Low-Cost Cryocooler Pumps Out Cheap DIY Liquid Nitrogen

July 15, 2024 by 18 Comments

A word of caution if you’re planning to try this cryocooler method for making liquid nitrogen: not only does it involve toxic and flammable gasses and pressures high enough to turn the works into a bomb, but you’re likely to deplete your rent account with money you’ll shell out for all the copper tubing and fittings. You’ve been warned.

In theory, making liquid nitrogen should be as easy as getting something cold enough that nitrogen in the air condenses. The “cold enough” part is the trick, and it’s where [Hyperspace Pirate]’s cryocooler expertise comes into play. His setup uses recycled compressors from cast-off air conditioners and relies on a mixed-gas Joule-Thomson cycle. He plays with several mixtures of propane, ethylene, methane, argon, and nitrogen, with the best results coming from argon and propane in a 70:30 percent ratio. A regenerative counterflow heat exchanger, where the cooled expanding gas flows over the incoming compressed gas to cool it, does most of the heavy lifting here, and is bolstered by a separate compressor that pre-cools the gas mixture to about -30°C before it enters the regenerative system.

There’s also a third compressor system that pre-cools the nitrogen process gas, which is currently supplied by a tank but will eventually be pulled right from thin air by a pressure swing adsorption system — basically an oxygen concentrator where you keep the nitrogen instead of the oxygen. There are a ton of complications in the finished system, including doodads like oil separators and needle valves to control the flow of liquid nitrogen, plus an Arduino to monitor and control the cycle. It works well enough to produce fun amounts of LN2 on the cheap — about a quarter of the cost of commercially made stuff — with the promise of efficiency gains to come.

It does need to be said that there’s ample room for peril here, especially containing high pressures within copper plumbing. Confidence in one’s brazing skills is a must here, as is proper hydro testing of components. That said, [Hyperspace Pirate] has done some interesting work here, not least of which is keeping expenses for the cryocooler to a minimum.

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How To Turn Cheap Speakers Into Something A Little Better

July 5, 2024 by 25 Comments

[Adam Francis] bought some cheap speaker drivers from AliExpress. Are they any good? Difficult to tell without a set of enclosures for them, so he made a set of transmission line cabinets. The resulting video proves that a decent sounding set of speakers shouldn’t have to cost the earth, and is quite entertaining to watch.

The design he’s going for is a transmission line, in effect a folded half-wave resonant tube terminated at one end and open at the other, with the speaker close to half way along. There is a lot of nuance to perfecting a speaker cabinet, but this basic recipe doesn’t have to be optimum to give a good result.

So after having some MDF cut to shape and glueing it all together, he ends up with some semi decent speakers for not a lot of money. The video is entertaining, with plenty of Britishisms, but the underlying project is sound. We’d have a pair on our bench.

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Make A Cheap Robot Mower Much Smarter

July 2, 2024 by 15 Comments

The Parkside range of tools as sold in European Lidl stores may be reasonably priced, but it contains some products of far better quality than their modest cost would suggest. This means that Parkside hacking has become as much of a cottage industry as IKEA hacking, and they’re a firm favorite for modifications. [Lambertus] has taken a Parkside robot mower, and converted it from a relatively mundane device to a fully-connected smart robot, with the aid of an ESP8266.

The hardware is surprisingly simple, as all that’s really needed is a stop/go command. This can be readily found by hooking up to the input from the mower’s rain sensor, allowing the ESP to control its operation. Then there’s an accelerometer to allow it to count motion, and a hookup tot he battery to measure voltage. The firmware uses ESPHome, resulting in a mower now connected to home automation.

This isn’t the first time we’ve shown you someone upgrading the smarts on  robot mover, and of course we’ve also taken a tour through the history of lawn mowers in general.

As Cheap As Chips: The MiFare Ultra Light Gets A Closer Look

June 26, 2024 by 7 Comments

If you take public transport in many of the world’s cities, your ticket will be an NFC card which you scan to gain access to the train or bus. These cards are disposable, so whatever technology they use must be astonishingly cheap. It’s one of these which [Ken Shirriff] has turned his microscope upon, a Montreal Métro ticket, and his examination of the MiFare Ultra Light it contains is well worth a read.

The cardboard surface can be stripped away from the card to reveal a plastic layer with a foil tuned circuit antenna. The chip itself is a barely-discernible dot in one corner. For those who like folksy measurements, smaller than a grain of salt. On it is an EEPROM to store its payload data, but perhaps the most interest lies in the support circuitry. As an NFC chip this has a lot of RF circuitry, as well as a charge pump to generate the extra voltages to charge the EEPROM. In both cases the use of switched capacitors plays a part in their construction, in the RF section to vary the load on the reader in order to transmit data.

He does a calculation on the cost of each chip, these are sold by the wafer with each wafer having around 100000 chips, and comes up with a cost-per-chip of about nine cents. Truly cheap as chips!

If NFC technology interests you, we’ve taken a deep dive into their antennas in the past.

Probably The Cheapest Mac Emulation Hardware

June 20, 2024 by 20 Comments

There are many ways to build your own Macintosh clone, and while the very latest models remain a little inaccessible, there are plenty of Intel-based so-called “Hackintoshes” which deliver an almost up-to-date experience. But the Mac has been around for a very long time now, and its earliest incarnation only has 128k of RAM and a 68000 processor. What can emulate one of those? Along comes [Matt Evans], with a working Mac 128k emulated on a Raspberry Pi Pico. Such is the power of a modern microcontroller that an RP2040 can now be a Mac!

The granddaddy of all Macs might have been a computer to lust after four decades ago, but the reality was that even at the time the demands of a GUI quickly made it under-powered. The RP2040 has plenty of processing power compared to the 68000 and over twice the Mac’s memory, so it seemed as though emulating the one with the other might be possible. This proved to be the case, using the Musashi 68000 interpreter and a self-built emulator which has been spun into a project of its own called umac. With monochrome VGA and USB for keyboard and mouse, there’s MacPaint on a small LCD screen looking a lot like the real thing.

If you want a 1980s Mac for anything without the joy of reviving original hardware, this represents an extremely cheap way to achieve it. If it can be compiled for microcontrollers with more available memory we could see it would even make for a more useful Mac, though your Mac mileage may vary.

Of course, this isn’t the only take on an early Mac we’ve brought you.

The Cheap CNC3018 Gets A Proper Revamp

June 8, 2024 by 24 Comments

Many people have been attracted to the low price and big dreams of the CNC3018 desktop CNC router. If you’re quick, you can pick one up on the usual second-hand sales sites with little wear and tear for a steal. They’re not perfect machines by any stretch of the imagination, but they can be improved upon, and undoubtedly useful so long as you keep your expectations realistic.

[ForOurGood] has set about such an improvement process and documented their journey in a whopping eight-part (so far!) video series. The video linked below is the most recent in the series and is dedicated to creating a brushless spindle motor on a budget.

As you would expect from such a machine, you get exactly what you pay for.  The low cost translates to thinner than ideal metal plates, aluminium where steel would be better, lower-duty linear rails, and wimpy lead screws. The spindle also suffers from cost-cutting, as does the size of the stepper motors. But for the price, all is forgiven. The fact that they can even turn a profit on these machines shows the manufacturing prowess of the Chinese factories.

We covered the CNC 3018 a while back, and the comments of that post are a true gold mine for those wanting to try desktop CNC. Warning, though: It’s a fair bit harder to master than 3D printing!

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