This Dual Extrusion System Rocks

Dual extrusion systems for 3D printers have been around for quite a few years, but the additional cost, complexity, and hassle of printing with them have kept them off the workbenches of most hackers. [Jón Schone] from Proper Printing has now thrown his own hat in the ring, with a custom dual extrusion rocker system that can swap extruders without any additional actuators.

The two extruders are mounted on a spring-loaded rocker mechanism, which holds the inactive extruder up and away from the printing surface. Extruders are swapped by moving the carriage to either end of the x-axis, where the v-wheel rolls a ramp and pops the rocker over, putting the new extruder in the center line of the carriage. There are 3 wheels at the top of the carriage, but only two are in contact with the rail at any time. While this system is more complex than simply mounting two extruders side-by-side, it reduces the chances of the inactive nozzle oozing onto the parts or scraping across the surface. The height of each extruder can be adjusted with a screw,  and any horizontal offset between the nozzles is checked with a calibration procedure and corrected in the firmware. See the full video after the break.

[Jón] is offering the design files and modified firmware to perform this mod on your own Ender 3 Pro (though he notes other Creality printers should be compatible), but you’ll still need to source a control board with the additional stepper driver and heater output for the second extruder. This is yet another in a long list of hacks he’s performed on this popular entry-level printer, such as a modification that allows you to fold the machine up and take it on the go.

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The Digital Radio Era (Partially) Ends In Ireland

It’s commonly agreed that the future of broadcast radio lies in the eventual replacement of AM and FM analogue transmissions with digital services. A wide range of technologies exist to service this change-over, and for much of the world the most visible of them has been Digital Audio Broadcasting, or DAB. This VHF service has slowly increased in popularity to the extent that in some countries the FM or AM switch-off process has already happened or is well under way. It’s thus a surprise to hear a piece of news from a country that’s going the other way, as the Irish broadcaster RTÉ is about to turn off its national DAB multiplex.

The reason cited is cost-effectiveness, the take up of DAB in the Republic by listeners is low (Northern Ireland having the UK multiplexes instead), and that the broadcaster is the only one maintaining a national multiplex. Our Irish friends tell us that as in other parts of the world the rural coverage can be patchy, and with only RTÉ and no commercial stations on offer it’s easy to see why the allure of a DAB set is lacking.

In case anyone is tempted to prophecy the demise of digital broadcasting from this news, that’s not the real story. This is simply an abandonment of DAB. Plenty of Irish people listen to the radio through digital media just as anywhere else, this is simply an indication that they’re choosing not to do so via DAB. The Irish DVB television multiplexes carry the same stations and more, and meanwhile, the inexorable rise of online listening through smart speakers and mobile phones has eaten DAB’s lunch. But it does raise the point for other places: when your mobile phone delivers any radio station or streaming service you desire and is always in your pocket, why would you want a radio?

For more on DAB including some of its shortcomings, a few years ago we took an in-depth look at the system.

Thanks [Laura] for the header image.

Tetris On Split-Flap Go Brrr

It hardly seems possible, but engineer collective and split-flap display purveyors [Oat Foundry] were able to build a working implementation of Tetris on a 10 x 40 split-flap display in the span of a single day. Check it out in the video after the break.

This project is a bit understaffed in the details department, but we do know that [Oat Foundry] started with [Timur Bakibayev]’s open-source implementation of Tetris in Python and modified the draw function to work on a split-flap display. As you may have guessed, the biggest obstacle is the refresh rate and how it affects playability — particularly during those tense moments when a player rotates a piece before dropping it. Split-flaps flip quickly from on to off, but flipping back to on requires a full trip around through all the other characters.

We think this is nice work for a one-day build. Should they go further, we’d like to see the same things implemented as [Oat Foundry] does: a high score tracker and a preview of the next piece.

Don’t have a split-flap display? Yeah, us either, but we do have televisions. Turn on the tube and check out this Nano-scale Tetris.

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Is That A Cat Or Not?

Pandemic induced boredom takes people in many different ways. Some of us go for long walks, others learn to speak a new language, while yet more unleash their inner gaming streamer. [Niklas Fauth] has taken a break from his other projects by creating a very special project indeed. A cat detector! No longer shall you ponder whether or not the object or creature before you is a cat, now that existential question can be answered by a gadget.

This is more of a novelty project than one of special new tech, he’s taken what looks to be the shell from a cheap infra-red thermometer and put a Raspberry Pi Zero with camera and a small screen into it. This in turn runs Tensorflow with the COCO-SSD object identification model. The device has a trigger, and when it’s pressed to photograph an image it applies the model to detect whether the subject is a cat or not. The video posted to Twitter is below the break, and we can’t dispute its usefulness in the feline-spotting department.

[Niklas] has featured here more than once in the past. This is not his only pandemic project, either.

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The IEEE Builds A Smart Watch

It used to be that building your own watch was either a big project or it meant that you didn’t really care about how something looked on your wrist. But now with modern parts and construction techniques, a good-looking smart watch isn’t out of reach of the home shop. But if you don’t want to totally do it yourself, you can turn to a kit and that’s what [Stephen Cass] did. Writing in IEEE Spectrum, he took a kit called a Watchy and put it through its paces for you.

Watchy is an open source product that uses an ESP32, an E-ink display, and costs about $50. The display is 1.5 inches — good enough for a watch — and it has a real time clock, a vibration motor, an accelerometer, and four buttons. The whole thing runs on a 200 mAh lithium polymer battery. The charger is microUSB and you can also upload software to it using the usual Arduino tools.

However, [Stephen] found that none of the examples he tried would work at first. He found problems with the Mac software, but he also had problems under Windows. The answer? Switching to a Raspberry Pi seemed to work and once the watch was wiped clean, the Mac tools would work, too. It sounds like this isn’t a common problem, but he has to erase the watch with the Pi before each programming cycle.

Unlike a normal Arduino program, all the work in a typical Watchy program happens in setup() so the watch can mostly sleep and it updates the 200×200 typically just once a minute. As an example, [Stephan] wrote a watch face that uses an old Irish alphabet to tell time. He plans to add code to grab online data, too, and the phone has support for connecting wirelessly and parsing JSON to make tasks like that easier.

We always thought the EZ430-Chronos was a good-looking watch, but its screen is dated now. You can also pick up a lot of cheap import watches that can be hacked.

Waterjet-Cut Precision Pastry

We need more high-end, geometric pastry in our lives. This insight is courtesy of a fairly old video, embedded below, demonstrating an extremely clever 2D CNC mechanism that cuts out shapes on a cake pan, opening up a universe of arbitrary cake topologies.

The coolest thing about this machine for us is the drive mechanism. A huge circular gear is trapped between two toothed belts. When the two belts move together the entire thing translates, but when they move in opposite directions, it turns. It seems to be floating on a plastic platform, and because the design allows the water-jet cutting head to remain entirely fixed, only a small hole underneath is necessary, which doubtless simplifies high-pressure water delivery and collection. Rounding the machine out are cake pans make up of vertical slats, like on a laser- or plasma-cutter table, that slip into registration pins and let the water pass through.

The kinematics of this machine are a dream, or perhaps a nightmare. To cut a straight line, it does a cycloid-shaped dance of translation and turning that you simply have to see in motion. Because of this intricate path, the cake-feed speed varies along the way, so this machine won’t be perfect for all applications and relies on a thin kerf. And we can’t help thinking how dizzy the cake must get in the process.

Indeed, the same company put out a relatively pedestrian two-arm motion cutter (another video!) that poses different kinematic problems. It’s essentially a two-arm plotter with a moving table underneath that helps increase the working area. Details are scarce, but it looks like they’re minimizing motion of the moving table, doing the high frequency small stuff with the stiff arms. Presumably someone turned the speed on the previous machine up to 11 and spun a cake off into the room, causing them to rethink the whole move-the-cake-around design.

Of course, watercut pastry isn’t limited to exotic CNC mechanisms. This (third!) video demonstrates that a simple Cartesian XY bot can do the job as well.

If you think about it, using high-pressure pure water to cut foodstuffs is a win on many levels. We’d just miss out on licking the knife. Thanks [Adam G DeMuri] for the awesome comment that lead us to a new world of watercut edibles.

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X-Ray Defeats Letterlocking — Unfolds And Reads Letter Sealed Since 1697

Over recent years we’ve been treated to a series of fascinating advances in the world of x-ray imaging, as  researchers have developed their x-ray microtomography techniques and equipment to the point at which they can probe and then computationally reconstruct written material within objects such as letters or scrolls in museum collections whose value or fragility means they can’t be opened and read conventionally. There is more to this challenge than simply extracting the writing though, in addition to detecting the ink the researchers also have to unpick the structure of whatever it was written upon. A particular challenge comes from letterpackets, the art of folding a letter into its own envelope, and a newly-published Nature Communications paper details work from a team of academics in the USA, the UK, and the Netherlands in tackling it.

Letterpackets were more than a practical method of packaging a missive for the mail, they also had a security function often called Letterlocking. A packet would be folded in such a way as to ensure it was impossible to open without tearing or otherwise damaging the paper, and their structure is of especial interest to historians. The researchers had a unique resource with which to work; the Brienne collection is a trunk full of undeliverable mail amassed by a 17th century postmaster couple in Den Haag in the Netherlands, and now in the possession of the Beeld en Geluid museum in that city. In it were a cache of letters including 577 never-opened letterpackets, and the x-ray technique promised a means to analyse these without compromising them.

A letter imaged using the technique.
A letter imaged using the technique.

The researchers have developed an entirely computational technique for the virtual unfolding process. Starting with a 3D volumetric x-ray scan of the unopened packet they then identify the various layers of paper and the bright spots which denote the ink. Their algorithm has to cope with areas in which two or more layers are tightly in contact, for example when multiple levels are folded, and then unpick the resulting 3-dimensional mesh into a 2-dimensional sheet. Their process for mapping the crease pattern involves applying a colour map representing the mean curve radius at a given point. The final section of the paper looks at the multiple different methods of letterlocking, and attempts to categorise them all including a security rating for each. It’s evident that this could be a highly personalised process, indeed they give as an example a letter from Mary Queen of Scots that used an intricate spiral folding technique to identify its sender.

It’s clear that this technique will reveal many more fascinating historical documents as it is both refined and extended across the many more collections of further artefacts that have lain waiting for it. As they say, individual letters do not necessarily contain earth-shattering historical discoveries, but taken together they shed an important light on the social history of past centuries.

One of the names on the paper is [David Mills], whose work has featured here before.