Prusa Unveils Their Own Line Of PLA Filament

September 21, 2018 by Tom Nardi 33 Comments

There’s little debate that the Original Prusa i3 MK3 by Prusa Research is just about the best desktop 3D printer you can buy, at least in its price bracket. It consistently rates among the highest machines in terms of print quality and consistency, and offers cutting edge features thanks to its open source iterative development. Unless you’re trying to come in under a specific budget, you really can’t go wrong with a Prusa machine.

But while the machine itself can be counted on to deliver consistent results, the same can’t always be said for the filament you feed into it. In a recent blog post, [Josef Prusa] explains that his team was surprised to see just how poor the physical consistency was on even premium brands of 3D printer filament. As a company that prides itself with keeping as much of the 3D printing experience under their control as possible, they felt they had an obligation to do better for their customers. That’s why they’ve started making their own filament which they can hold to the same standards as the rest of their printer.

Their new filament, which is aptly called “Prusament”, is held to higher physical standards of not only diameter but ovality. Many manufacturers simply perform spot checks on the filament’s diameter, but this can miss bulges or changes in its cross-sectional shape. On your average 3D printer this might cause some slightly uneven extrusion and a dip in print quality, but likely not a failure. But the Prusa i3 MK3, specifically with the Multi Material upgrade installed, isn’t most printers. During testing even these slight variations were enough to cause jams.

But you won’t have to take their word for it. Every spool of Prusament will have a QR code that points to a page which tells you the exact production date, length, percent ovality, and standard diameter deviation of that particular roll. An interactive graph will even allow you to find the filament’s diameter for a specific position in the spool, as well as determine how much filament is remaining for a given spool weight. It should be very interesting to see what the community will do with this information, and we predict some very interesting OctoPrint plugins coming down the line.

Prusament is currently only available in PLA, but PETG and ASA variants are coming soon. You can order it now directly from Prusa Research in Prague for $24.99 per kilogram, but it will also be available on Amazon within the month for help keep the shipping costs down.

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The N64 Controller Gets Brass Gears Through 3D Printing

September 21, 2018 by Brian Benchoff 36 Comments

The controller for the Nintendo 64 is a masterpiece of design, and despite being more than two decades old, people are still using this controller competitively. Smash Bros, you know. Those competitive gaming enthusiasts are hard on their controllers, and after decades and tournaments, the analog stick will wear out. Previously, this required a rebuild or simply replacing the entire controller. Now there’s another option: a completely re-engineered analog stick, all made possible thanks to 3D printing.

[Nam Le] is a student at Cal Poly, and as would be expected for a very specific subset engineering students, had to track down new N64 controller every few months. The stick on these controllers wear out, so [Nam] decided to make the most durable joystick that has ever fit inside an N64 controller.

The design of the N64 stick is pretty simple, and exactly what you would expect if you’ve ever opened up an analog joystick. There’s the stick itself, which is connected to gears on the X and Y axes, which are in turn connected to encoders. This entire assembly sits in a bowl. After twenty years, the mating surface between the stick and the gears wear down, and the bowl becomes deformed. The solution here is obviously to engineer something sturdier, and despite what most of the 3D printing community will tell you, ABS and PLA just won’t cut it.

[Nam] re-designed the gears and bowl out of brass using lost-wax casting using 3D printed parts. These brass parts were mated with 3D printed gears and an enclosure for the bowl. The stick is nylon, an important design choice because this is the first part to wear down anyway, and it’s also the easiest part to replicate. Yes, this is designing an analog stick for the strength of materials and Real Engineering™ for those of you keeping track at home.

Right now, the joystick works as intended, and lasts much longer than the stock version. The goal now is to get this stick tournament-legal for some serious Smash time, in the hopes of not replacing controllers every few months.

555 Timer Robots Will Rule The World

September 21, 2018 by Steven Dufresne 21 Comments

A running joke we see in the comments by Hackaday readers whenever a project includes an Arduino or Raspberry Pi that seems like overkill is to proclaim that “I could have done it with a 555 timer!” That’s especially the case if the project amounts to a blinking light or anything which oscillates. Well [Danko Bertović] has made a whole robot out of a 555 timer circuit in his latest Volos Projects video.

Okay, it’s really a dead bug circuit in the shape of a robot but it does have blinking lights. We also like how the base is the battery, though some unevenness under it seems to make the whole thing a bit unstable as you can see in the video below. There are also a few parts which are cosmetic only. But it’s cute, it’s a 555 timer circuit, and it’s shaped like a robot. That all makes it a win.

We do wonder how it can be taken further. After all, a walk cycle is a sort of oscillation so the 555 timer circuit could run some servo motors or at least some piezoelectric feet. Ideas anyone?

On the other hand, if you’re looking for a dead bug circuit which belongs in a fine arts museum then you need look no further than The Clock.

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New Part Day: Put An Alexa In Everything

September 20, 2018 by Brian Benchoff 54 Comments

The last great hope for electronics manufactures is smart home assistants. The Alexas and Siris and OK Googles are taking over homes across the country. At its best, it’s HAL 9000, only slightly less homicidal. It will entertain your children, and you can order cat litter just by saying you want cat litter. This is the future, whether we like it or not.

In an attempt to capture the market, Amazon has released the Alexa Connect Kit. This is an Amazon-Echo-On-a-Chip — a piece of hardware that adds Alexa to microwaves, blenders, and whatever other bit of home electronics you can imagine.

The Alexa Connect Kit is the hardware behind Amazon’s efforts to allow developers easy integration with Alexa. The options for adding Alexa to a product up until now have been using Zigbee to connect an Echo Show or Echo Plus, or simply giving a device the ability to connect to an Echo through Bluetooth. The Alexa Connect Kit, however, is a pure hardware solution that puts Alexa in anything.

Unfortunately you can’t get one yet. Right now, the Alexa Connect Kit is just a preview, and if you want to get your hands on one — or get any specs on this bit of hardware — you’ll need to apply to the developer program. We’ve signed up and will share and juicy details that come our way as part of the program.

According to the Wall Street Journal (try Google referral link if you hit the pay wall), several companies are already working on integrating the Alexa Connect Kit into their existing product lines. Hamilton Beach and Procter & Gamble are both working on something, although the press doesn’t say what kind of device will now be loaded up with a voice assistant. Amazon, however, has a microwave using the technology that the owner can, “command the microwave to do things like defrost a half-pound of chicken, or set it up to automatically reorder a favorite type of popcorn on Amazon”.

Despite the sparse details, this is relatively game-changing when it comes to the world of homebrew electronics. We’ve seen dozens of projects using hacked Raspberry Pis and other microcontrollers to at Alexa to hacked coffee machines, to shoot Nerf darts, and to control a projector. If you can actually get one of these Alexas-on-a-chip, all those projects could be done with one simple piece of hardware.

One Man’s Journey To Becoming His Own ISP

September 20, 2018 by Drew Littrell 119 Comments

America is a BIG country. There are pockets all across the land where broadband Internet is slow-to-nonexistent, and many individuals are left with wireless cell service as their only means of internet connection. This is the situation [Brandt Kuykendall] found himself in upon moving his family to Dillon Beach, CA. So he started up his own fiber ISP. (YouTube, embedded below.)

“Cell phone service was really our only option, but that proved to be extremely expensive. My wife came home with the bill (of) $707, and that was the last straw.”

Despite being a mere two hours from the technological hub of San Francisco [Brandt] found himself dissatisfied with the level of service he was receiving from his provider. However, instead of shredding his current contract altogether he decided to go directly to the source. He tracked down the location of the AT&T cell tower in his area and made every call he could in order to find out who was in charge of “opening up the taps”. Months of negotiation between AT&T and [Brandt] ensued and eventually resulted in a fiber line being installed directly into his garage.

The story didn’t stop there, because [Brandt] took it upon himself to spread the wealth by providing his neighbors with Wi-Fi access to the fiber optic line in exchange for a small monthly fee. Employing the use of industrial-grade small cell transmitters he essentially created a point-to-point network along his neighbors’ roofs. [Brandt’s] garage serves as the network monitoring hub enabling him to diagnose any traffic issues. What began as one man seeking decent internet speeds burgeoned into a journey to becoming his own ISP which now serves over 100 other residents of the Dillon Beach area.

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Fixing An IBM 1401 Computer To Get It Printing Again

September 20, 2018 by Steven Dufresne 10 Comments

The IBM 1401 is a classic computer which IBM marketed throughout the 1960s, late enough for it to have used transistors rather than vacuum tubes, which is probably a good thing for this story. For small businesses, it was often used as their main data processing machine along with the 1403 printer. For larger businesses with mainframes, the 1401 was used to handle the slower peripherals such as that 1403 printer as well as card readers.

The Computer History Museum in Mountain View, CA has two working 1401s as well as at least one 1403 printer, and recently whenever the printer printed out a line, the computer would report a “print check” error. [Ken Shirriff] was among those who found and fixed the problem and he wrote up a detailed blog entry which takes us from the first test done to narrow down the problem, through IBM’s original logic diagrams, until finally yanking out the suspect board and finding the culprit, a germanium transistor which likely failed due to corrosion and an emitter wire that doesn’t look solidly connected. How do they know that? In the typical [Ken]-and-company style which we love, they opened up the transistor and looked at it under a microscope. We get the feeling that if they could have dug even deeper then they would have.

If you’re unfamiliar with the work of this team who maintain the machines at the museum, you’ll want to read up on how they recently got a 1401 to run FORTRAN II code.

C64 Keyboard Helps Keep The Memory Alive

September 20, 2018 by Tom Nardi 11 Comments

To say that the Commodore 64 was an important milestone in the history of personal computing is probably a bit of an understatement. For a decent chunk of the 1980s, it was the home computer, with some estimates putting the total number of them sold as high as 17 million. For hackers of a certain age, there’s a fairly good chance that the C64 holds a special spot in their childhood; perhaps even setting them on a trajectory they followed for the rest of their lives.

At the risk of showing his age, [Clicky Steve] writes in to tell us about the important role the C64 played in his childhood. He received it as a gift on his fifth birthday from his parents, and fondly remembers the hours he and his grandfather spent with a mail order book learning how to program it. He credits these memories with getting him interested in technology and electronic music. In an effort to keep himself connected to those early memories, he decided to build a modern keyboard with C64 keycaps.

As you might expect, the process started with [Steve] harvesting the caps from a real Commodore, in fact, the very same computer he received as a child. While the purists might shed a tear that the original machine was sacrificed to build this new keyboard, he does note that his C64 had seen better days.

Of course, you can’t just pull the caps off of C64 and stick them on a modern keyboard. [Steve] found the STLs for a 3D printable C64 to Cherry MX adapter on GitHub, and had 80 of them professionally printed as he doesn’t have access to an SLS printer. He reports the design works well, but that non-destructively removing the adapters from the caps once they are pressed into place probably isn’t going to happen; something to keep in mind for others who might be considering sacrificing their personal C64 for the project.

[Steve] installed the caps on a Preonic mechanical keyboard, which worked out fairly well, though he had to get creative with the layout as the C64 caps didn’t really lend themselves to the keyboard’s ortholinear layout. He does mention that switches a bit heavier than the Cherry MX Whites he selected would probably be ideal, but overall he’s extremely happy with his functional tribute to his grandfather.

If you’re more of a purist, you can always adapt the C64 keyboard directly to USB. Or go in the complete opposite direction and put a Raspberry Pi into a C64 carcass.