Casting CNC Parts In Aluminium

April 16, 2019 by 19 Comments

When it comes to machining, particularly in metal, rigidity is everything. [Tailortech] had a homebuilt CNC machine with a spindle held in place by a plastic bracket. This just wasn’t up to the job, so the decision was made to cast a replacement.

[Tailortech] decided to use the lost PLA process – a popular choice amongst the maker crowd. The spindle holder was first sketched out, then modeled in Fusion 3D 360. This was then printed in PLA slightly oversized to account for shrinkage in the casting process.

The PLA part was then used to make a plaster mold. [Tailortech] explains the process, and how to avoid common pitfalls that can lead to problems. It’s important to properly heat the mold once the plaster has set to remove moisture, but care must be taken to avoid cracking or wall calcination. It’s then necessary to slowly heat the mold to even higher temperatures to melt out the PLA prior to casting. With the mold completed, it can be filled with molten aluminium to produce the final part. When it’s cooled off, it’s then machined to final tolerances and installed on the machine.

Lost PLA casting is a versatile process, and goes to show that not everything has to be CNC machined out of billet to do the job. It’s also readily accessible to any maker with a furnace and a 3D printer. If you’ve got a casting project of your own, be sure to let us know. Video after the break.

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Circular Linear Motor Becomes A Micro Motor Raceway

April 16, 2019 by 19 Comments

Over on Hackaday.io we have a lot of people playing around with the possibilities presented by cheap printed circuit boards. Whether that means making a quadcopter from fiberglass or a speaker from etched copper, we’ve seen just about everything. Now, finally, we have a miniature magnetic racetrack. It’s an ant highway, or a linear motor wrapped around into a circle. Or a tiny-scale model railroad. Either way it’s very, very cool.

The ant highway comes from [bobricius], one of the many makers tinkering around with coils and traces. This time he’s built a ten centimeter square board that is, effectively, a linear motor. It’s a three-phase motor made out of PCB coils, with a small magnetic ‘car’ that’s pushed forward. These coils are controlled by an ATtiny10 and a trio of MOSFETs. Wrap that linear motor into a circle and you have a neat little circular track that’s the smallest model car raceway you’ve ever seen.

As with all of [bobricius]’ circuit boards, this one demands a video, and that’s available below. This is an interesting bit of technology, and it’s more than just a raceway for tiny magnetic cars. This could be the beginnings of an analog clock with a digital heart, or the start of the smallest model train layout you’ve ever seen. There’s impressive work being done with PCB motors now that printed circuit boards are so cheap, and we can’t wait to see what’s next.

A quick Hackaday search will reveal [bobricius] as a prolific source of projects whose work we’ve featured multiple times. Favorites include a brushless PCB motor, and an FR4 cell phone.

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Piezoelectric Antennas For Very, Very Low Frequencies

April 16, 2019 by 41 Comments

If you want to talk about antennas, the amateur radio community has you covered, with one glaring exception. Very low frequency and Extremely Low Frequency radio isn’t practiced very much, ultimately because it’s impractical and you simply can’t transmit much information when your carrier frequency is measured in tens of Hertz. There is more information on Extremely Low Frequency radio in Michael Crichton’s Sphere than there is in the normal parts of the Internet. Now there might be an easier way to play with VLF radiation, thanks to developers at the National Accelerator Laboratory. They’ve developed a piezoelectric transmitter for very long wavelengths.

Instead of pushing pixies through an antenna, this antenna uses a rod-shaped crystal of lithium niobate, a piezoelectric material. An AC voltage is applied to the rod makes it vibrate, and this triggers an oscillating electric current flow that’s emitted as VLF radiation. The key is that it’s these soundwaves bouncing around that define the resonant frequency, and the speed of sound in lithium niobate is a lot slower than the speed of light, but they’re translated into electric signals because of its piezoelectricity. For contrast, if this were a wire quarter-wave antenna it would be tens of kilometers long.

The application for this sort of antenna is ideally for where regular radio doesn’t work. Radio doesn’t work underwater, but nuclear subs trail an antenna out of the back to receive messages using Extremely Low Frequency radio. A walkie talkie doesn’t work in a mine, and this could potentially be used there. There is a patent for this piezoelectric antenna, so if anyone knows of a source of lithium niobate, put a link in the comments.

We’ve seen this trick before to make small antennas even smaller, but this is the first time we’ve seen it used in the VLF band, where it’s arguably even more impressive.

Picking The Right Sensors For Home Automation

April 16, 2019 by 22 Comments

Imagine that you’re starting a project where you need to measure temperature and humidity. That sounds easy in the abstract, but choosing a real device out of many involves digging into seemingly infinite details and trade-offs that come with them. If it’s a low-stakes monitoring project, picking the first sensor that comes to mind might suffice. But when the project aims to control an AC system in an office of temperature-sensitive coders, it pays to take a hard look at the source of all information: the sensor.

Continuing a previous article I would like to use that same BMaC project from that article as a way to illustrate how even a couple of greenhorns can figure out how to pick everything from environmental sensors to various actuators, integrating it into a coherent system that in the end actually does what it should.

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Concrete USB Hub Isn’t Going Anywhere

April 16, 2019 by 10 Comments

When starting a new project, the choice of material can have a big effect on the character of the finished product. Wood is stylish and has a certain elegance to it, while polished or brushed aluminium is great for a more futuristic feel. Sometimes though, you just want big, cheap and heavy – in which case, concrete is your friend!

[BALES] was short on USB ports, and needed a hub with plenty of connectivity. Concrete had the benefits of being solid and heavy, and also impervious to beverages. Thus, a melamine form was produced, chosen as its surface doesn’t give the concrete anything to grab on to. A foam skull was cut out and added to create an inlay for decoration, and the 7-port octopus-style hub was placed inside.

With careful attention paid to the mixture consistency, the concrete was poured into the mold and allowed to set. Care was taken to avoid air bubbles and to ensure the mixture flowed completely into the mold, without leaving air pockets behind the inserted components. After allowing it to set for a few days, the part was demolded, with care taken to minimise edge crumbling. The foam skull was removed, and infilled with black epoxy, with a little more used to coat the top and sides of the hub. As a finishing touch, a foam pad was fitted to the base to allow it to sit on a desk without scratching everything up.

In the end, [BALES] has ended up with a hefty hub that won’t skitter around when plugging and unplugging devices. It should also serve admirably as a sturdy drink coaster on those cold winter nights. If you’re trying a similar project yourself, note that sometimes concrete can be surprisingly conductive. Video after the break.

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How 5G Is Likely To Put Weather Forecasting At Risk

April 16, 2019 by 90 Comments

If the great Samuel Clemens were alive today, he might modify the famous meteorological quip often attributed to him to read, “Everyone complains about weather forecasts, but I can’t for the life of me see why!” In his day, weather forecasting was as much guesswork as anything else, reading the clouds and the winds to see what was likely to happen in the next few hours, and being wrong as often as right. Telegraphy and better instrumentation made forecasting more scientific and improved accuracy steadily over the decades, to the point where we now enjoy 10-day forecasts that are at least good for planning purposes and three-day outlooks that are right about 90% of the time.

What made this increase in accuracy possible is supercomputers running sophisticated weather modeling software. But models are only as good as the raw data that they use as input, and increasingly that data comes from on high. A constellation of satellites with extremely sensitive sensors watches the planet, detecting changes in winds and water vapor in near real-time. But if the people tasked with running these systems are to be believed, the quality of that data faces a mortal threat from an unlikely foe: the rollout of 5G cellular networks.

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Rooting Your Ride: Jailbreaking A Subaru QNX

April 16, 2019 by 18 Comments

A modern car still drives in the same way as the one you would have bought thirty years ago, it still has a steering wheel and all the other controls. What has changed in the cabin lies mostly beneath the dash, where enough computing power to launch several Moon shots takes care of everything from air-conditioning to entertainment. As you might expect these systems attract the curiosity of security researchers, and through their work we gain an insight into their operation.

[Scott Gayou] has a Subaru, a car that has an all-in-one entertainment system head unit that is typical of what you’d find across a host of manufacturers. His account of jailbreaking it is a lengthy essay and a fascinating read for anyone. He starts with a serial port, then an SSH prompt for a root password, and a bit of searching to find it was made by Harman and that it runs the closed-source realtime OS QNX. From there he finds an official Subaru update, from which he can slowly peel away the layers and deduce the security mechanism. The write-up lays bare his techniques, for example at one point isolating the ARM assembler for a particular function and transplanting it bodily into his own code for investigation.

Eventually he could penetrate the filesystem of the update, and from there he could find that while the root user had a password there were two other accounts that while heavily locked down, had none. The discovery came that files on USB drives plugged into the system were given user-level execute permissions, at which point under the locked-down user he could execute arbitrary code from USB drives. He could then create and modify copies of the device’s filesystem which he could flash onto it, and thus place a modified password validation function into it and gain root access.

Some Hackaday readers will be accomplished in security work such as this, but many of us are hardware specialists for whom it remains something of a dark art. A comprehensive and accessible write-up such as this one is therefore invaluable, because it gives us an insight into the techniques used and perhaps more importantly, into some of the security pitfalls a hardware engineer might unwittingly introduce into their creations.

QNX is a real-time operating system with a long history of appearances in industrial and automotive applications. Readers with long memories may recall their demo floppies from the 1990s which packed a fully functional GUI, Internet connectivity, and modern (for the time) web browser onto a single 1.44Mb floppy disk. We’ve talked about it in the past in a little detail, as when someone made a desktop OS using it.