Getting Geared Up For Home Powder Coating

September 24, 2023 by 17 Comments

[Blondihacks] wanted to do powder coating for a model train without a lot of special equipment. She started with an Eastwood kit that runs about $230. Depending on the options, you can get the gun by itself for between $110 – $170. However, you will need more than just this kit. You can see how [Blondihacks] used the kit in the video below.

The idea behind powder coating is simple: an electrostatic charge attracts a powder — usually some polymer — and makes it stick to an item. Then heat or UV light turns the powder into a hard finish much tougher than paint. Powder coating can be thicker than paint and doesn’t run, either.

The gun requires a small air compressor, and you need an electric oven, which could be a toaster oven. It probably shouldn’t be an oven you plan to use for food. It should also be in a well-ventilated area, plus you’ll want a respirator or dust mask. [Blondhacks] used a portable paint booth so as not to spew powder everywhere, which looked nice, although you could just use a big cardboard box. A custom jig to hang the parts while spraying, and she was ready to go.

If you are on a budget, by the way, you can get a kit from Harbor Freight for a bit less. It probably has fewer accessories, and we don’t know how it compares, but it is an option for much less money. Either way, you need a small air pressure regulator, and you also need a dryer and a filter for the air because you need dry and clean air so as not to contaminate the powder.

The part is grounded, and the gun charges the powder as it sprays. Once coated, you stick the part in the oven for about 20 minutes. The results look good and, compared to a painted part, the coating was super tough. For intricate parts, you can heat the part and then dip it in fluid-like powder. If you prefer to stick to regular powder coating, we have some tips.

Continue reading “Getting Geared Up For Home Powder Coating” →

Books You Should Read: David Macaulay’s Architecture Series

September 21, 2023 by 31 Comments

For a lot of us, there’s a bright line separating the books we enjoyed as children from the “real” books of our more mature years. We all eventually age out of the thin, brightly illustrated picture books we enjoyed in our youth, replacing them with thicker, wordier volumes with fewer and fewer illustrations, until they become so dense with information that footnotes and appendices are needed to convey all the information, and a well-written index is a vital necessity to make use of any of it.

Such books seem like a lot less fun than kids’ books, and they probably are, but most of us adjust to the change and accept the fact that the children’s section of the library doesn’t hold much that’ll interest us anymore. But not all the books that get a “JUV” label on their spines are created equal. Some are far more than picture books, even if the pictures are the main attraction. The books of British-born American author David Macaulay come to mind, particularly the books comprising his Architecture Series.

Macaulay’s books were enormously influential in developing my engineering sensibilities, and are still a pleasure to thumb through these many years later. I still learn something about the history of construction and engineering when I pull one of these books off the shelf, which makes them Books You Should Read.

Continue reading “Books You Should Read: David Macaulay’s Architecture Series” →

You’ve Got Mail: Reading Addresses With OCR

September 20, 2023 by 14 Comments

Last time I delivered on this column, I told you about the USPS’ attempts to fully automate a post office. Of course, that’s a bit of a misnomer, since it took 1,500 employees to actually operate the place on a daily basis. Although Project Turnkey in Rhode Island and Project Gateway in California were proving grounds for all kinds of mail sorting and processing equipment, the act of actually reading addresses and routing mail to its final destination still required human intervention and hand coding.

Today, the post office processes hundreds of millions of mail pieces each day using various pieces of equipment. One of those important pieces of equipment is the OCR address reader, which manages to make sense of all kinds of chicken scratch.

Continue reading “You’ve Got Mail: Reading Addresses With OCR” →

Rocker Bogie Suspension: The Beloved Solution To Extra-Planetary Rovers

September 14, 2023 by 18 Comments

When navigating the vast and unpredictable expanses of outer space, particularly on the alien terrains of distant planets, smart engineering often underlies every major achievement. A paramount example of this is the rocker bogie suspension system. It’s an integral component of NASA’s Mars rovers and has become an iconic feature in its own right. Its success has seen the design adopted by the Indian space program and thousands of hobbyists in turn.

So, what exactly is it that makes rocker bogie suspension such a compelling design solution? Let’s dive into the engineering that makes these six-wheeled wonders so special.

Continue reading “Rocker Bogie Suspension: The Beloved Solution To Extra-Planetary Rovers” →

How Three Letters Brought Down UK Air Traffic Control

September 13, 2023 by 51 Comments

The UK bank holiday weekend at the end of August is a national holiday in which it sometimes seems the entire country ups sticks and makes for somewhere with a beach. This year though, many of them couldn’t, because the country’s NATS air traffic system went down and stranded many to grumble in the heat of a crowded terminal. At the time it was blamed on faulty flight data, but news now emerges that the data which brought down an entire country’s air traffic control may have not been faulty at all.

Armed with the official incident report and publicly available flight data, Internet sleuths theorize that the trouble was due to one particular flight: French Bee flight 731 from Los Angeles to Paris. The flight itself was unremarkable, but the data which sent the NATS computers into a tailspin came from two of its waypoints — Devil’s Lake Wisconsin and Deauville Normandy — having the same DVL identifier. Given the vast distance between the two points, the system believed it was looking at a faulty route, and refused to process it. A backup system automatically stepped in to try and reconcile the data, but it made the same determination as the primary software, so the whole system apparently ground to a halt.

It’s important to note that there was nothing wrong with the flight plan entered in by the French Bee pilots, and that early stories blaming faulty data were themselves at fault. However we are guessing that air traffic software developers worldwide are currently scrambling to check their code for this particular bug. We’re fortunate indeed that safety wasn’t compromised and only inconvenience was the major outcome.

Air traffic control doesn’t feature here too often, but we’ve previously looked at a much earlier system.

Header image: John Evans, CC BY-SA 2.0.

Electro-Optical Control Of Lasers With A Licorice Twist

September 5, 2023 by 8 Comments

You’ve got to hand it to [Les Wright]; he really knows how to dig into optical arcana and present topics in an interesting way. Case in point: an electro-optical control cell that’s powered by ouzo.

OK, the bit about the Greek aperitif may be stretching things a bit, but the Kerr Cell that [Les] builds in the video below does depend on anethole, the essential component of aniseed extract, which lends its aromatic flavor to everything from licorice to Galliano and ouzo. As [Les] explains, the Kerr effect uses a high-voltage field to rapidly switch light passing through a medium on and off. The most common medium in Kerr cells is nitrobenzene, a “distressingly powerful organic solvent” with such fun side effects as toxicity, flammability, and carcinogenicity.

Luckily, [Les] found a suitable substitute in the form of anethole — a purified sample, not just an ouzo nip. The solution went into a plain glass cuvette equipped with a pair of aluminum electrodes, which got connected to one of the high-voltage supplies we’ve seen him build before for his nitrogen laser. A pair of polarizing filters go on either end of the cuvette, and are adjusted to blank out the light passing through it. Applying 45 kilovolts across the cell instantly turns the light back on. Watch it in action in the video below.

There’s a lot of room left for experimentation on this one, including purification of the anethole for potentially better results. We’d also be curious if plain ouzo would show some degree of Kerr effect. For science, of course.

Continue reading “Electro-Optical Control Of Lasers With A Licorice Twist” →

Clean Up Your Resin-Printing Rinse With Dialysis

September 5, 2023 by 64 Comments

There’s a lot to like about resin 3D printing. The detail, the smooth surface finish, the mechanical simplicity of the printer itself compared to an FDM printer. But there are downsides, too, not least of which is the toxic waste that resin printing generates. What’s one to do with all that resin-tainted alcohol left over from curing prints?

How about sending it through this homebrew filtering apparatus to make it ready for reuse? [Involute] likens this process to dialysis, and while we see the similarities, what’s going on here is a lot simpler than the process used to filter wastes from the blood in patients with failing kidneys — there are no semipermeable membranes used here. Not that the idea suffers from its simplicity, mind you; it just removes unpolymerized resin from the isopropyl alcohol rinse using the same photopolymerization process used during printing. Continue reading “Clean Up Your Resin-Printing Rinse With Dialysis” →