Spinning Threads Put The Bite On Filament In This Novel Extruder Design

October 20, 2021 by Dan Maloney 29 Comments

When it comes to innovation in FDM 3D printing, there doesn’t seem to be much room left to move the needle. Pretty much everything about filament printing has been reduced to practice, with more or less every assembly available off the shelf. Even the business end — the extruder — is so optimized that there’s not much room left for innovation.

Or is there? The way [David Leitner] sees it, there is, which is why he built this rolling-screw extruder (if you can get to the Thingiverse link, [David] cross-posted on reddit, too). Standard extruders work on the pinch-roller principle, where the relatively soft filament is fed past a spring-loaded gear attached to a stepper motor. The stepper rotates the gear, which either advances the filament into or retracts it from the hot end. [David]’s design instead uses a trio of threaded rods mounted between two rings. The rods are at an angle relative to the central axis of the rings, forming a passage that’s just the right size for the filament to fit in. When the rings spin, the threads on the rods engage with the filament, gripping it around its whole circumference and advancing or retracting it depending on which way it’s spinning. The video below shows it working; we have to admit it’s pretty mesmerizing to watch.

[David] himself admits there’s not much advantage to it, perhaps other than a lower tendency to skip since the force is spread over the entire surface of the filament rather than just a small pinch point. Regardless, we like the kind of thinking that leads to something like this, and we’ll bet there are probably unseen benefits to it. And maybe the extruder actually is a place for innovation after all; witness this modular nozzle swapping system.

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An Arduino Nano connected to a portable tape recorder

Audio Tape Interface Revives Microcassettes As Storage Medium

October 20, 2021 by Robin Kearey 37 Comments

In the early 1980s cassette tapes were the standard storage medium for home computer users; readers of a certain age will remember fiddling with audio jacks, tape counters and signal levels, then waiting for several minutes while a program (hopefully) loaded correctly. While most people happily upgraded to much more reliable floppy disks, [Zack Nelson] decided to go back in time and add a suitably classic storage medium to a retrocomputing project, in the form of a cassette interface. The cassette player he had available was a Pearlcorder L400, which uses the smaller microcassette instead of the familiar audio tapes used in your Walkman or boombox.

[Zack] designed the entire thing from the ground up: first he decided to use differential Manchester encoding, which provides immunity against common disturbances like speed variations (which cause wow and flutter). The data is encoded in the frequency range from 1 kHz to 2 kHz, which suits the bandwidth of the cassette player. Next, he designed the interface between the computer and the tape recorder; built from an op-amp and a comparator with a handful of discrete components, it filters the incoming signal and clips it to provide a clean digital signal to be read out directly by the computer.

The system is demonstrated by hooking it up to an Arduino Nano, which reads out the data stream at about 3000 baud. The noise it makes should bring back memories to anyone brought up with the “PRESS PLAY ON TAPE” message; if it inspires you to make your own, we’re happy to report that full schematics and source code are available. [Zack] is not the first one to make his own cassette interface; we’ve seen a somewhat more complicated analog design before, as well as one based on an FPGA.

Flickering Jack O’ Lantern Is An Easy Beginner Build

October 19, 2021 by Lewin Day 8 Comments

The Jack o’ Lantern is a fun Halloween tradition, though one that does come with a few risks. It’s pretty easy to slice off a bit of finger when carving a stiff pumpkin, and candles draw more enmity from fire crews than most household items. For the electronics beginner looking for a learning project, [Oyvind’s] build might be a nice safe bet.

The build starts with a 3D-printed pumpkin figurine with a suitably spooky face, though [Oyvind] notes there’s nothing stopping this project from being executed with a real orange gourd instead. Inside, an Arduino is hooked up to a trio of orange LEDs. They’re attached to PWM pins and each is given a random brightness value at regular intervals to create a pleasant flickering effect.

It’s a very simple project, but it’s also the kind of thing that’s perfect for introducing new people into the world of electronics. There’s little to get wrong, and mistakes aren’t costly, making it an ideal project for beginners. From there, the sky really is the limit! Video after the break.

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Sign Detects RF To Show You Are On The Air

October 19, 2021 by Al Williams 2 Comments

Like a lot of hams, [Stuart] wanted an “on the air” sign. These signs often connect to a PTT switch or maybe an output from the transmitter that also does things like switches antennas or switches in an amplifier. [Stuart’s] version, though, simply senses the radio frequency emissions from the transmitter and lights up that way. You can see two videos about the sign, below.

Honestly, we are a little worried that he might have too much RF at his operating position. Presumably, the device is pretty sensitive, especially if there’s any actual antenna on the sign. A comparator and a pot let you set the sensitivity so it doesn’t light up when your garage door opens.

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A homebrew telephone connects home and workshop.

The Calls Are Coming From Inside The House (or Workshop)

October 19, 2021 by Kristina Panos 16 Comments

Hot on the heels of their carbon microphone build a few years ago, [Simplifier] strung up a two-phone network between the house and the workshop. Both telephones are completely DIY except for the pair of switches on the front. Each side has a bell, a microphone, and an audio transformer. Listening is done through a pair of headphones, and both users speak through a homebrew carbon microphone.

We particularly love the bell, which is made from fence post caps. Sitting between the bells and ready to strike is a ball bearing mounted on a really thick piece of wire that’s driven by an electromagnet. To make a call, you use both switches — the one on the left pulls either the bell or the microphone to ground, while the switch on the ~~left~~ right is used momentarily to send 6 V from the lantern battery down the 50 ft. line to the other phone to ring it. You’ll see what we mean in the demo video after the break. Check out the sound of those fence post caps!

[Simplifier] wound an audio transformer that provides the necessary impedance matching to use regular headphones as receivers. Since the homebrew microphones only need 1.5 V, [Simplifier] split the voltage across two carbon contacts placed in series. That’s still more than necessary, but [Simplifier] was able to make it work.

More recently, [Simplifier] has built a beautiful and even better carbon microphone and even hosted a back-to-basics Hack Chat.

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ESP32 Clock Pushes Outrun Graphics Over Composite

October 19, 2021 by Tom Nardi 24 Comments

We’ve covered plenty of clocks powered by the ESP32, but this one from [Marcio Teixeira] is really something special. Rather than driving a traditional physical display, the microcontroller is instead generating a composite video signal of an animated digital clock. This could be fed into whatever device you wish, but given the 80’s synthwave style it’s pumping out, you’ll probably want to find a suitably retro CRT to do it justice.

Specifically this is a variant of the “Dali” clock, where each digit seems to melt and morph into its successor. Though his version doesn’t necessarily share code with all the previous iterations, [Marcio] does credit the developers who have pulled off similar visual tricks going all the way back to 1979. Given the vintage of this particular animation, the neon skyline and infinite scrolling grid certainly feel like a perfect fit.

Want to add a little vaporwave vibe to your own workbench? Assuming you’ve already got a 80s style CRT, all you need is an ESP32 and two wires stuck into the composite video port. One goes to ground, and the other goes to the chip’s analog pin. Once everything is powered up, you’ll be able to configure the clock with a web-based interface. It doesn’t get much easier than that.

In the documentation, [Marcio] calls out a few open source projects which were instrumental to getting his clock off the ground. The pioneering work [bitluni] did to get video out of the ESP32 is something of a given, but he also sends a hat tip to [rossumur] for his collection of 8-bit game console emulators written for the microcontroller. Projects like this are a fantastic example of what’s possible when a community works together to truly push the envelope.

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Turning Old Masks Into 3D Printer Filament

October 19, 2021 by Tom Nardi 23 Comments

Disposable masks have been a necessity during the COVID-19 pandemic, but for all the good they’ve done, their disposal represents a monumental ecological challenge that has largely been ignored in favor of more immediate concerns. What exactly are we supposed to do with the hundreds of billions of masks that are used once or twice and then thrown away?

If the research being conducted at the University of Bristol’s Design and Manufacturing Futures Lab is any indication, at least some of those masks might get a second chance at life as a 3D printed object. Noting that the ubiquitous blue disposable mask is made up largely of polypropylene and not paper as most of us would assume, the team set out to determine if they could process the masks in such a way that they would end up with a filament that could be run through a standard 3D printer. While there’s still some fine tuning to be done, the results so far are exceptionally impressive; especially as it seems the technique is well within the means of the hobbyist.

The first step in the process, beyond removing the elastic ear straps and any metal strip that might be in the nose, is to heat a stack of masks between two pieces of non-stick paper with a conventional iron. This causes the masks to melt together, and turn into a solid mass that’s much easier to work with. These congealed masks were then put through a consumer-grade blender to produce the fine polypropylene granules that’re suitable for extrusion.

Mounted vertically, the open source Filastruder takes a hopper-full of polypropylene and extrudes it into a 1.75 mm filament. Or at least, that’s the idea. The team notes that the first test run of filament only had an average diameter of 1.5 mm, so they’re modifying the nozzle and developing a more powerful feed mechanism to get closer to the goal diameter. Even still, by cranking up the extrusion multiplier in the slicing software, the team was able to successfully print objects using the thin polypropylene filament.

This is only-during-a-pandemic recycling, and we’re very excited to see this concept developed further. The team notes that the extrusion temperature of 260 °C (500 °F) is far beyond what’s necessary to kill the COVID-19 virus, though if you planned on attempting this with used masks, we’d imagine they would need to be washed regardless. If the hacker and maker community were able to use their 3D printers to churn out personal protective equipment (PPE) in the early days of the pandemic, it seems only fitting that some of it could now be ground up and printed into something new.