Hybrid Rocket Engine Combines Ceramic Aerospike With 3D Printed Fuel

May 13, 2021 by 23 Comments

[Integza] has worked hard over the last year, crafting a variety of types of rocket and jet engine, primarily using 3D printed parts. Due to the weaknesses of plastic, all of which conflict with the general material requirements for an engine that gets hot, he has had less thrust and more meltdowns than he would have liked. Undeterred, he presses on, now with a hybrid rocket aerospike design. The goal? Actually generating some thrust for once!

The latest project makes the most of what [Integza] has learned. The aerospike nozzle is 3D printed, but out of a special thick ceramic-loaded resin, using a Bison 1000 DLP printer. This allowed [Integza] to print thicker ceramic parts which shrunk less when placed in a kiln, thus negating the cracking experienced with his earlier work. The new nozzle is paired with a steel rocket casing to help contain combustion gases, and the rocket fuel is 3D printed ASA plastic. 3D printing the fuel is particularly cool, as it allows for easy experimentation with grain shape to tune thrust profiles.

With the oxygen pumping, the new design produces some thrust, though [Integza] is yet to instrument the test platform to actually measure results. While the nozzles are still failing over a short period of time, the test burns were far less explosive – and far more propulsive – than his previous efforts. We look forward to further development, and hope [Integza’s] designs one day soar high into the sky. Video after the break.

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Piggy Bank Slot Machine Puts A Spin On Saving

May 12, 2021 by 7 Comments

Saving money is inherently no fun until the time comes that you get to spend it on something awesome. Wouldn’t you be more likely to drop your coins into a piggy bank if there was a chance for an immediate payout that might exceed the amount you put in? We know we would. And the best part is, if you put such a piggy bank slot machine out in the open where your friends and neighbors can play with it, you’ll probably make even more money. As they say, the house always wins.

Drop a coin in the slot and it passes through a pair of wires that act as a simple switch to start the reels spinning. Inside is an Arduino Uno and a giant printed screw feeder that’s driven by a small stepper motor and a pair of printed gears. The reels have been modernized and the display is made of four individual LED matrices that appear as a single unit thanks to some smoky adhesive film.

This beautiful little machine took a solid week of 3D printing, which includes 32 hours wasted on a huge piece that failed twice. [Max 3D Design] tried rotating the model 180° in the slicer and thankfully, that solved the problem. Then it was on to countless hours of sanding, smoothing with body filler, priming, and painting to make it look fantastic.

If you want to make your own, all the files are up on Thingiverse. The code isn’t shown, but we know for a fact that Arduino slot machine code is out there already. Check out the build and demo video after the break.

As much as we like this build’s simplicity, it would be more slot machine-like if there was a handle to pull. Turns out you can print those, too.

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3D Printed Transistor Goes Green

May 12, 2021 by 29 Comments

We’ll be honest, we were more excited by Duke University’s announcement that they’d used carbon-based inks to 3D print a transistor than we were by their assertion that it was recyclable. Not that recyclability is a bad thing, of course. But we would imagine that any carbon ink on a paper-like substrate will fit in the same category. In this case, the team developed an ink from wood called nanocelluose.

As a material, nanocellulose is nothing new. The breakthrough was preparing it in an ink formulation. The researchers developed a method for suspending crystals of nanocellulose that can work as an insulator in the printed transistors. Using the three inks at room temperature, an inkjet-like printer can produce transistors that were functioning six months after printing.

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Sit Pretty On Would-Be Garbage With An Upcycled Chair

May 12, 2021 by 21 Comments

What’s the coolest thing about doing upholstery work? Aside from the fact that you end up with a new thing to sit on, sometimes the work only involves clever stapling, and no sewing is necessary. Such is the case with [wyldestyle]’s upcycled jeans chair, which started as a bare-wood swivel number from the dump. In fact, this project is almost completely made from recycled materials, except of course for those staples that hold it all together. And really, that heavy-duty stapler is likely the fanciest tool you’d need to make your own.

[wyldestyle] didn’t have any furniture foam, and we think that stuff is too expensive, anyway. So the padding treatment begins with a piece of thick Styrofoam that covers the seat screws and bolts. This is glued in place and trimmed down to match the contours of the chair’s seat and back.

Here’s where things gets tricky: the next step is wrapping over the stiff foam board with a few layers of that foam sheeting stuff that’s often used as packing material. This sheeting needs to be taut, but pull it too tight, and it will rip.

To add some loft to the chair, [wyldestyle] stretched and stapled the stuffing from an old pillow that was headed for the garbage. The final step is strategically scissoring jean scraps to fit, then stretching and stapling those to cover all the layers underneath. We like the way this chair looks, and would probably try to place pockets somewhere useful, like the back of the chair.

It’s a shame that so much denim goes to waste all over the world. There’s often a lot of life left in most of the fabric, which can be repurposed into all kinds of things, including eyeglasses frames using a wicked set of jigs.

Otters Deliver A High Power Stationary Audio Experience

May 12, 2021 by 20 Comments

Our favorite raft of otters is back at it again with another display of open source audio prowess as they bring us the OtterCastAmp, the newest member of the OtterCast family of open source audio multitools. If you looked at the previous entry in the series – the OtterCastAudio – and thought it was nice but lacking in the pixel count or output power departments then this is the device for you.

The Amp is fundamentally a very similar device to the OtterCastAudio. It shares the same Allwinner S3 Cortex-A application processor and runs the same embedded Linux build assembled with Buildroot. In turn it offers the same substantial set of features and audio protocol support. It can be targeted by Snapcast, Spotify Connect or AirPlay if those are your tools of choice, or act as a generic PulseAudio sink for your Linux audio needs. And there’s still a separate line in so it source audio as well.

One look at the chassis and it’s clear that unlike the OtterCastAudio this is not a simple Chromecast Audio replacement. The face of the OtterCastAmp is graced by a luscious 340×800 LCD for all the cover art your listening ear can enjoy. And the raft of connectors in the back (and mountain of inductors on the PCBA) make it clear that this is a fully fledged class D amplifier, driving up to 120W of power across four channels. Though it may drive a theoretical 30W or 60W peak across its various outputs, with a maximum supply power of 100W (via USB-C power delivery, naturally) the true maximum output will be a little lower. Rounding out the feature set is an Ethernet jack and some wonderfully designed copper PCB otters to enjoy inside and out.

As before, it looks like this design is very close to ready for prime time but not quite there yet, so order at your own risk. Full fab files and some hints are linked in the repo mentioned above. If home fabrication is a little much it looks like there might be a small manufacturing run of these devices coming soon.

Historical Hackers: Emergency Antennas Launched By Kite

May 12, 2021 by 24 Comments

Your airplane has crashed at sea. You are perched in a lifeboat and you need to call for help. Today you might reach for a satellite phone, but in World War II you would more likely turn a crank on a special survival radio.

These radios originated in Germany but were soon copied by the British and the United States. In addition to just being a bit of history, we can learn a few lessons from these radios. The designers clearly thought about the challenges stranded personnel would face and came up with novel solutions. For example, how do you loft a 300-foot wire up to use as an antenna? Would you believe a kite or even a balloon?

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