How Not To Design A 3D Printed Belt Clamp

December 16, 2018 by 17 Comments

[Mark Rehorst] has been busy with his Ultra MegaMax Dominator (UMMD) design for a 3D printer, and one of the many things he learned in the process was how not to design a 3D printed belt clamp. In the past, we saw how the UMMD ditched the idea of a lead screw in favor of a belt-driven Z axis, but [Mark] discovered something was amiss when the belts were flopping around a little, as though they had lost tension. Re-tensioning them worked, but only for a few days. It turned out that the belt clamp design he had chosen led to an interesting failure.

The belts used were common steel-core polyurethane GT2 belts, and the clamp design uses a short segment of the same belt to lock together both ends, as shown above. It’s a simple and effective design, but one that isn’t sustainable in the longer term.

The problem was that this design led to the plastic portion of the belt stretching out and sliding over the internal steel wires. The stretching of the polyurethane is clear in the image shown here, but any belt would have had the same problem in the clamp as it was designed. [Mark] realized it was a much better idea to use a design in which the belts fold over themselves, so the strain is more evenly distributed.

[Mark] has been sharing his experiences and design process when it comes to building 3D printers, so if you’re interested be sure to check out the UMMD and its monstrous 695 mm of Z travel.

AI Bot Plays Castlevania So You Don’t Have To

December 16, 2018 by 10 Comments

We’re not allowed to have TV here in the Hackaday Wonder Bunker, but occasionally we’ll pool together the bandwidth credits they pay us in and gather ’round the old 3.5 inch TFT LCD to watch whatever Netflix assures us is 93% to our liking. That’s how we found out they’ve made a show based on, of all things, one of the Castlevania games for the NES. We wanted to play the game to understand the backstory, but since it hails from the era of gaming where primitive graphics had to be supplemented with soul-crushing difficulty, we didn’t get very far.

But thanks to a very impressive project developed by [Michael Birken] maybe we’ll have it all figured out by the time we’ve saved enough credits to watch Season 2 (no spoilers, please). The software, which he’s quick to point out is not an example of machine learning, is an attempt to condense his personal knowledge of how to play Castlevania into a plugin for the Nintaco NES emulator. The end result is CastlevaniaBot, which is capable of playing through the original Castlevania from start to finish without human intervention. You can even stop and start it at will, so it can play through the parts you don’t want to do yourself.

[Michael] started this project with a simple premise: if he could make a bot successfully navigate the many levels of Dracula’s castle, then getting it to kill a few monsters along the way should be easy enough. Accordingly, he spent a lot of time perfecting the path-finding for CastlevaniaBot, which included manually playing through the entire game in order to get an accurate map of the background images. These images were then analyzed to identify things like walls and stairs, so the bot would know where it could and couldn’t move protagonist Simon Belmont. No matter what the bot is doing during the game it always considers where it is and where it needs to be going, as there’s a time limit for each stage to contend with. Continue reading “AI Bot Plays Castlevania So You Don’t Have To” →

OpenLH: Automating Biology For Everyone

December 16, 2018 by 9 Comments

When we took a biology lab, you had to use a mouth pipette to transfer liquids around. That always seemed odd to use your mouth to pick up something that could be dangerous. It’s also not very efficient. A modern lab will use a liquid handling robot, but these aren’t exactly cheap. Sometimes these are called pipettors and even a used one on eBay will set you back an average of $1,000 — and many of them much more than that. Now there’s an open source alternative, OpenLH, that can be built for under $1,000 that leverages an open source robot arm. You can find a video about the system below.

The robot arm, a uArm Swift Pro, is the bulk of the cost.  The Pro can also operate as a 3D printer or a laser engraver with a little work. In fact, we wondered if you could use the arm to make a 3D printer and then print the parts you need to convert it to a liquid handler. Seems like it should work.

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Brushless Motor Thrust Stand Provides Useful Data

December 16, 2018 by 16 Comments

When designing model aircraft of any shape or size, it’s useful to know the performance you can expect from the components chosen. For motors and propellers, this can be difficult. It’s always best to test them in combination. However, with the numbers of propeller and motor combinations possible, such data can be tough to come by. [Nikus] decided it would be easier to just do the testing in-house, and built a rig to do so.

The key component in this build is the strain gauge, which comes already laced up with an Arduino-compatible analog-digital converter module. Sourced for under $10 from Banggood, we can’t help but think that we’ve got it easy in 2018. A sturdy frame secures motor and propeller combination to the strain gauge assembly. An ATMEGA328 handles sending commands to the motor controller, reading the strain gauge results, and spitting out data to the LCD.

It’s a cheap and effective build that solves a tricky problem and would be a useful addition to the workshop for any serious modeler. We’ve seen other approaches in this area too, for those eager to graph their motor performance data. Video after the break.

[Thanks to Baldpower for the tip!]

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Shape Shifting Structures Work With Magnets

December 15, 2018 by 12 Comments

In The Dark Knight, Lucius Fox shows Bruce Wayne a neat bit of memory weave fabric. In its resting state, it is a light, flexible material, but when an electrical current is applied, it pops into a pre-programmed shape. That shape could be a tent or a bat-themed paraglider. Science has not caught up to Hollywood in this regard, but the concept has been demonstrated in a material which increases its rigidity up to 318% within one second when placed in a magnetic field. Those numbers do not mean a lot by themselves, but increasing rigidity in a reversible, non-chemical way is noteworthy.

The high-level explanation is that hollow tubes are 3D printed and filled with magnetorheological fluid which becomes more viscous in the presence of a magnet because the ferrous suspended particles bunch up to form chains instead of sliding over one another. Imagine a bike tire filled with gel, and when you need a little extra traction the tire becomes softer, but when you are cruising on a paved trail, the tire becomes as hard as a train wheel to reduce friction. That could be darn handy in more places than building a fast bike.

Manhattan Mystery Of Creepy Jingles And Random Noises Solved

December 15, 2018 by 23 Comments

Here’s a puzzler for you: If you’re phreaking something that’s not exactly a phone, are you still a phreak?

That question probably never crossed the minds of New Yorkers who were acoustically assaulted on the normally peaceful sidewalks of Manhattan over the summer by creepy sounds emanating from streetside WiFi kiosks. The auditory attacks caused quite a stir locally, leading to wild theories that Russian hackers were behind it all. Luckily, the mystery has been solved, and it turns out to have been part prank, part protest, and part performance art piece.

To understand the exploit, realize that New York City has removed thousands of traditional pay phones from city sidewalks recently and replaced them with LinkNYC kiosks, which are basically WiFi hotspots with giant HDTV displays built into them. For the price of being blitzed with advertisements while strolling by, anyone can make a free phone call using the built-in VOIP app. That was the key that allowed [Mark Thomas], an old-school phreak and die-hard fan of the pay telephones that these platforms supplanted, to launch his attack. It’s not exactly rocket surgery; [Mark] dials one of the dozens of conference call numbers he has set up with pre-recorded audio snippets. A one-minute delay lets him crank the speakerphone volume up to 11 and abscond. The recordings vary, but everyone seemed most creeped out by the familiar jingle of the [Mr. Softee] ice cream truck franchise, slowed down and distorted to make it sound like something from a fever dream.

Yes, it’s a minimal hack, and normally we don’t condone the misuse of public facilities, even ones as obnoxious as LinkNYC appears to be. But it does make a statement about the commercialization of the public square, and honestly, we’re glad to see something that at least approaches phreaking again. It’s a little less childish than blasting porn audio from a Target PA system, and far less dangerous than activating a public safety siren remotely.

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Imploding Tiny 3D Prints

December 15, 2018 by 10 Comments

If you think about 3D printing, the ultimate goal would be to lay down specific atoms or molecule and build anything. Despite a few lab demonstrations at that scale, generally, it is easier to print in the macro scale than the micro. While it won’t get down to the molecule level, implosion fabrication is a new technique researchers hope will allow you to print large things and then shrink them. The paper describing the process appeared in Science. If you don’t want to pay your way through the paywall, you can read a summary on NewScientist or C&EN. Or you can scour the usual sources.

The team at MIT uses the same material that is found in disposable diapers. A laser traces patterns and the light reacts to a chemical implanted in the diaper material (sodium polyacrylate). That material can swell to many times its normal size which is why it is used in diapers. In this case, though, the material is swollen first and then reduced back to normal size.

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