Creating A Laser Cutter From A 3D Printer

June 10, 2019 by 32 Comments

The average FDM 3D printer is not so different from your garden variety laser cutter. They’re often both Cartesian-coordinate based machines, but with different numbers of axes and mounting different tools. As [Gosse Adema] shows, turning a 3D printer into a laser cutter can actually be a remarkably easy job.

The build starts with an Anet A8 3D printer. It’s an affordable model at the lower end of the FDM printer market, making it accessible to a broad range of makers. With the help of some 3D printed brackets, it’s possible to replace the extruder assembly with a laser instead, allowing the device to cut and engrave various materials.

[Gosse] went with a 5500 mW diode laser, which allows for the cutting and engraving of wood, some plastics and even fabrics. Unlike a dedicated laser cutter there are no safety interlocks and no enclosure, so it’s important to wear goggles when the device is operating. Some tinkering with G-Code is required to get things up and running, but it’s a small price to pay to get a laser cutter on your workbench.

We’ve seen [Gosse]’s 3D printer experiments before, with the Anet A8 serving well as a PCB milling machine.

Takata’s Deadly Airbags: An Engineering Omnishambles

June 10, 2019 by 116 Comments

Engineers are, for the time being, only human. This applies even more so to executives, and all the other people that make up a modern organisation. Naturally, mistakes are made. Some are minor, while others are less so. It’s common knowledge that problems are best dealt with swift and early, and yet so often they are ignored in the hopes that they’ll go away.

You might have heard the name Takata in the news over the last few years. If that name doesn’t ring a bell you’ve likely heard that there was a major recall of airbag-equipped vehicles lately. The story behind it is one of a single decision leading to multiple deaths, scores of injuries, a $1 billion fine, and the collapse of a formerly massive automotive supplier.

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This Clapperboard Prints Movie Posters

June 10, 2019 by 3 Comments

The clapperboard is a device used in video to synchronize audio and video. Its role in movies is well known and its use goes back in one form or another to the 1920s. [Gocivici] is a big movie fan and created a clapperboard that is able to print out posters of recently announced movies when the clapper is clapped.

The poster is not a big, full color job, but rather a black and white one, roughly the size of a movie ticket. [Gocivici] keeps his movie tickets in a journal and wanted to be able to keep small posters in there along with them. A thermal printer is used to print the poster along with the title, the release date, and some information about the movie. In addition to the printer, the hardware involved is a Raspberry Pi, a switch, and an LED. The clapperboard itself is 3d printed and then painted. A bit of metal is used to keep the clappers apart and give a bit of resistance when pressing them together. A nice touch is a metal front, so you can use magnets to keep your posters on the board.

[Gocivici] has detailed build instructions up along with a video (available after the break) showing the printer in action. The 3d models are available as well as the code used to create the posters after grabbing data from TMDb. If you need your clapperboard to be as accurate as possible, take a look at this atomic clock clapperboard.

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Running Linux On A Thermostat

June 10, 2019 by 8 Comments

When your thermostat comes with Linux running on it, that’s not a hack. When it doesn’t, and you get Linux on there yourself, it most definitely is. This is exactly what [cz7asm] has done. In a recent video, he shows the Honeywell thermostat booting Linux and running a wide range of software.

While the hardware inside the thermostat doesn’t afford all the luxuries of a typical modern embedded Linux, it’s got enough room for the basics. The system runs from a 1 MB rootfs in RAM, and has a 2.5 MB kernel image, leaving a spare 12 MB for everything else. With just these meager resources, [cz7asm] shows how the system can use a USB network adapter, connecting to telehack.com for some command-line retro fun, and host a web server, although no browser runs yet. There’s also framebuffer support for displaying graphics and animations, and the usual Linux terminal goodness.

All we’ve seen so far is the video, so we hope [cz7asm] posts the code somewhere, because we’re tired of using our thermostat just to run the AC.

You might remember [cz7asm] from his previous thermostatic triumph: running Doom. Check out the video of the latest thermostat adventure after the break.

Thanks to [Piecutter] for the tip!

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A Wii Playing The GameCube, Disguised As A Game Boy SP

June 9, 2019 by 3 Comments

It may be hard to believe, but thanks to the expert work of Nintendo aficionado [Bill Paxton], the Game Boy Advance SP and GameCube lovechild that you see before you started its life as a Wii. That means not only can it play commercial GameCube and Wii games, but also has access to the wide library of homebrew games and emulators available for those systems.

To create this marvel, [Bill] first had to expertly cut away extraneous components from the Wii’s motherboard. He then mated the “trimmed” PCB to a new board that holds the controls as well as some other ancillary components such as the audio amplifier and USB port. He even managed to squeeze a battery in there, as demonstrated in the video after the break.

Finally, he designed a 3D printed enclosure that incorporates GameCube-style controls (complete with printed buttons) into the classic clamshell Game Boy SP shape. Because of the complexity of the design, [Bill] decided to have it professionally printed at Shapeways rather than trying to run it off of his home printer, which he says helps sells the professional look. It did take him some trial and error before he got the hang of painting the printed material to his satisfaction, but we think the end result was certainly worth the effort.

It probably won’t come as a huge surprise to find that this isn’t the first time [Bill] has pulled off a stunt like this. A few years back he created a very similar “GameCube SP”, but by the looks of it, this revised attempt improves on the original version in every way possible.

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Hackaday Links: June 9, 2019

June 9, 2019 by 11 Comments

The Chicago Pile led to the Manhattan Project, which led to the atomic bomb. In Germany, there were similar efforts with less success, and now we have physical evidence from the first attempted nuclear reactor in Germany. In Physics Today, there’s a lovely historical retrospective of one of the ‘fuel cubes’ that went into one of Germany’s unsuccessful reactor experiments. This is a five-centimeter cube that recently showed up in the hands of a uranium collector. In the test reactor, six hundred of these cubes were strung along strings and suspended like a chandelier. This chandelier was then set inside a tub surrounded by graphite. This reactor never reached criticality — spectroscopy tells us the cube does not contain fission products — but it was the best attempt Germany made at a self-sustaining nuclear reaction.

The biggest failing of the Arduino is the pinout. Those header pins aren’t all on 0.1″ centers, and the board itself is too wide to fit on a single solderless breadboard. Here’s the solution to that problem. It’s the BreadShield, an Arduino Uno-to-Breadboard adapter. Plug an Uno on one end, and you get all the pins on the other.

There’s a new listing on AirBnB. this time from NASA. They’re planning on opening the space station up to tourism, starting at $35,000 USD per night. That’s a cool quarter mil per week, launch not included. The plan appears to allow other commercial companies (SpaceX and whoever buys a Boeing Starliner) to accept space tourists, the $35k/night is just for the stop at the ISS. Costs for launch and landing are expected to be somewhere between $20 and $60 Million per flight. Other space tourists have paid as much: [Dennis Tito], the first ‘fee-paying’ space tourist, paid $20M for a trip to the ISS in 2001. [Mark Shuttleworth] also paid $20M a year later. Earlier space ‘tourists’ paid a similar amount; Japanese journalist [Toyohiro Akiyama] flew to Mir at a cost of between $12M and $37M. Yes, the space station is now an AirBnB, but it’s going to cost twenty million dollars for the ride up there.

We’re getting into conference season, and there are two hardware cons coming up you should be aware of. The first is Hardwear.io, keynoted by [Christopher Tarnovsky], famous for DirecTV hacks. There will be other talks by [@TubeTimeUS] on cloning the Sound Blaster and [John McMaster] on dropping acid. All of this is going down this week at The Biltmore in Santa Clara, CA. The second upcoming conference of note is Teardown, the hardware conference put on by Crowd Supply. That’s in Portland, June 21-23, with a presence from the Church of Robotron.

GPS And ADS-B Problems Cause Cancelled Flights

June 9, 2019 by 80 Comments

Something strange has been going on in the friendly skies over the last day or so. Flights are being canceled. Aircraft are grounded. Passengers are understandably upset. The core of the issue is GPS and ADS-B systems. The ADS-B system depends on GPS data to function properly, but over this weekend a problem with the quality of the GPS data has disrupted normal ADS-B features on some planes, leading to the cancellations.

What is ADS-B and Why Is It Having Trouble?

Automatic Dependent Surveillance-Broadcast (ADS-B) is a communication system used in aircraft worldwide. Planes transmit location, speed, flight number, and other information on 1090 MHz. This data is picked up by ground stations and eventually displayed on air traffic controller screens. Aircraft also receive this data from each other as part of the Traffic Collision Avoidance System (TCAS).

ADS-B isn’t a complex or encrypted signal. In fact, anyone with a cheap RTL-SDR can receive the signal. Aviation buffs know how cool it is to see a map of all the aircraft flying above your house. Plenty of hackers have worked on these systems, and we’ve covered that here on Hackaday. In the USA, the FAA will effectively require all aircraft to carry ADS-B transponders by January 1st, 2020. So as you can imagine, most aircraft already have the systems installed.

The ADS-B system in a plane needs to get position data before it can transmit. These days, that data comes from a global satellite navigation system. In the USA, that means GPS. GPS is currently having some problems though. This is where Receiver autonomous integrity monitoring (RAIM) comes in. Safety-critical GPS systems (those in planes and ships) cross-check their current position. If GPS is sending degraded or incorrect data, it is sent to the FAA who displays it on their website. The non-precision approach current outage map is showing degraded service all over the US Eastern seaboard, as well as the North. The cause of this signal degradation is currently unknown.

What Hardware is Affected?

GPS isn’t down though — you can walk outside with your cell phone to verify that. However, it is degraded. How a plane’s GPS system reacts to that depends on the software built into the GPS receiver. If the system fails, the pilots will have to rely on older systems like VOR to navigate. But ADS-B will have even more problems. An aircraft ADS-B system needs position data to operate.  If you can’t transmit your position information, air traffic controllers need to rely on old fashioned radar to determine position. All of this adds up to a safety of flight problem, which means grounding the aircraft.

Digging through canceled flight lists, one can glean which aircraft are having issues. From the early reports, it seems like Bombardier CRJ 700 and 900 have problems. Folks on Airliners.net are speculating that any aircraft with Rockwell Collins flight management systems are having problems.

This is not a small issue, there are hundreds or thousands of canceled flights. The FAA set up a teleconference to assess the issue. Since then, the FAA has issued a blanket waiver to all affected flights. They can fly, but only up to 28,000 feet.

This is a developing story, and we’ll be keeping an eye on it. Seeing how the industry handles major problems is always educational, and there will be much to learn in the coming days.