When you want to build a large format 3D printer, you can’t just scale up the design of a desktop machine. In an excellent four-part build series (videos after the break), [Dr. D-Flo] takes us through all the engineering challenges he had to contend with when building a 3D printer with a 4x4x4 ft (1.2 m cube) print volume.
For such a large print volume you won’t be printing with a 0.4 mm nozzle. The heart of the printer is a commercial Massive Dimension MDPH2 pellet extruder, capable of extruding ~1 kg of plastic per hour through 1.5 mm to 5 mm nozzles. To feed the extruder, [Dr. D-Flo] used a Venturi vacuum system to periodically suck pellets from a large hopper. The system is driven by compressed air, which can introduce moisture back into the carefully dried pellets. To reduce the humidity levels, the compressed air passes through a series of vertical aluminum tubes to allow moisture to condense and drain out the bottom.
At 8.4 kg, it needs a powerful motion platform to move it. [Dr. D-Flo] went with a stationary bed design, with the extruder pushed around by seven high torque NEMA23 motors on a large gantry built from C-beam aluminum extrusions. A machine this size needs to be very rigid with well-fitting parts, so [Dr. D-Flo] made heavy use of CNC machined aluminum parts.
To allow dynamic bed leveling, [Dr. D-Flow] made use of a Quad Gantry Leveling (GQL) scheme. This means that each of the four Z-actuators will dynamically adjust its position based on inputs from the leveling probe. The avoid stressing the corner mountings that hold the X-Y gantry to the Z carriage plates, he used radial spherical bearings at the mounting points to allow a few degrees of play.
The build plate consists of an aluminum plate bolted onto the base in 25 positions with springs for adjustability. A massive 6000 watt 220 V heating pad sticks to the bottom, while the actual printing surface is a large sheet of borosilicate glass. One major concern was the deflection of the build plate when heated to working temperature, but with all the adjustment options [Dr. D-Flo] was able to get height variation down to about 0.25 mm. This is within the acceptable range when printing with layer heights of 1 mm or more.
The average person’s perception of a ham radio operator, assuming they even know what that means, is more than likely some graybeard huddled over the knobs of a war-surplus transmitter in the wee small hours of the morning. It’s a mental image that, admittedly, isn’t entirely off the mark in some cases. But it’s also a gross over-simplification, and a generalization that isn’t doing the hobby any favors when it comes to bringing in new blood.
In reality, a modern ham’s toolkit includes a wide array of technologies that are about as far away from your grandfather’s kit-built rig as could be — and there’s exciting new protocols and tools on the horizon. To ensure a bright future for amateur radio, these technologies need to be nurtured the word needs to be spread about what they can do. Along the way, we’ll also need to push back against stereotypes that can hinder younger operators from signing on.
On the forefront of these efforts is Amateur Radio Digital Communications (ARDC), a private foundation dedicated to supporting amateur radio and digital communication by providing grants to scholarships, educational programs, and promising open source technical projects. For this week’s Hack Chat, ARDC Executive Director Rosy Schechter (KJ7RYV) and Staff Lead John Hays (K7VE) dropped by to talk about the future of radio and digital communications.
Rosy kicked things off with a brief overview of ARDC’s fascinating history. The story starts in 1981, when Hank Magnuski had the incredible foresight to realize that amateur radio packet networks could benefit from having a dedicated block of IP addresses. In those early days, running out of addresses was all but unimaginable, so he had no trouble securing 16.7 million IPs for use by licensed amateur radio operators. This block of addresses, known as AMPRNet and then later 44Net, was administered by volunteers until ARDC was formed in 2011 and took over ownership. In 2019, the decision was made to sell off about four million of the remaining IP addresses — the proceeds of which went into an endowment that now funds the foundation’s grant programs.
Of all the recipients of ARDC grants, the M17 project garnered the most interest during the Chat. This community of open source developers and radio enthusiasts is developing a next-generation digital radio protocol for data and voice that’s unencumbered by patents and royalties. In their own words, M17 is focused on “radio hardware designs that can be copied and built by anyone, software that anyone has the freedom to modify and share to suit their own needs, and other open systems that respect your freedom to tinker.” They’re definitely our kind of folks — we first covered the project in 2020, and are keen to see it develop further.
John says the foundation has approximately $6 million each year they can dole out, and that while there’s certainly no shortage of worthwhile projects to support as it is, they’re always looking for new applicants. The instructions and guides for grant applications are still being refined, but there’s at least one hard requirement for any project that wants to be funded by the ARDC: it must be open source and available to the general amateur population.
Of course, all this new technology is moot if there’s nobody to use it. It’s no secret that getting young people interested in amateur radio has been a challenge, and frankly, it’s little surprise. When a teenager can already contact anyone on the planet using the smartphone in their pocket, getting a ham license doesn’t hold quite the same allure as it did to earlier generations.
Depending on how old you are, this might have been one of the most shocking moments in Stranger Things.
The end result is that awareness among youth is low. During the Chat, one participant recounted how he had to put Netflix’s Stranger Things on pause so he could explain to his teenage son how the characters in the 1980s set show were able to communicate across long distances using a homemade radio. Think about that for a minute — in a show about nightmarish creatures invading our world from an alternate dimension, the hardest thing for this young man to wrap his head around was the fact a group of teenagers would be able to keep in touch with each other without the Internet or phone lines to connect them.
So its no surprise that John says the ARDC is actively looking for programs which can help improve the demographics of amateur radio. The foundation is looking to not only bring younger people onboard, but also reach out to groups that have been traditionally underrepresented in the hobby. As an example, he points to a grant awarded to the Bridgerland Amateur Radio Club (BARC) last year to bolster their youth engagement program. Funds went towards putting together a portable rig that would allow students to communicate with the International Space Station, and the development of hands-on workshops where teens will be able to launch, track, and recover payloads on a high altitude balloon. Let’s see them do that on their fancy new smartphone.
We want to not only thank Rosy Schechter and John Hays for taking part in this week’s Hack Chat, but everyone else at Amateur Radio Digital Communications for their efforts to support the present and future of amateur radio and digital communication.
The Hack Chat is a weekly online chat session hosted by leading experts from all corners of the hardware hacking universe. It’s a great way for hackers connect in a fun and informal way, but if you can’t make it live, these overview posts as well as the transcripts posted to Hackaday.io make sure you don’t miss out.
Carver is a famous name in audio equipment although they have been known to use odd names for things. For example, the 1980’s vintage M-400 magnetic field power amplifier that [JohnAudioTech] is repairing (see the two videos below). That sounds like something off a bad Star Trek remake, but, apparently, we weren’t alone in thinking that, judging by this 1982 review of the unit from a UK magazine.
Still, it is an interesting high-power amplifier and we love seeing gear of this age torn apart. The beast is rated at 201 watts — you have to wonder if the extra watt is another marketing ploy.
There were actually two units and they looked pretty good for four-decade-old boxes. One sounded pretty good outside of some noticeable buzzing. The other had something shorted inside. If you enjoy watching repair videos, you’ll appreciate this two-parter.
We have to admit — and it may be a personal bias — there is something more pleasing about seeing a PCB populated with a bunch of interesting-looking through-hole components. Modern boards with a sea of surface mount parts tend to look a little bland, aesthetically speaking. Of course, when it comes time to make our own boards, we are happy to use SMD and forego all that hole drilling!
[Jan Mrázek] is on a quest to make your resin 3D prints more accurate, more functional, and less failure prone. Let’s start off with his recent post on combating resin shrinkage.
When you want a part to have a 35 mm inner diameter, you probably have pretty good reasons, and when you draw a circle in your CAD software, you want a circle to come out in the real world. Resin shrinkage can put a kink in both of these plans. [Jan] identifies three culprits: resin squeezing, resin shrinkage, and exposure bleeding. And these three factors can add up in unexpected ways, so that you’ll get a small reference cube when you print it on its own, but large reference cubes when printed as a group. [Jan]’s article comes with a test piece that’ll help you diagnose what’s going on. Continue reading “Fighting All That Can Go Wrong With Resin”→
Agriculture on any scale involves many tasks that require lifting, hauling, pushing, and pulling. On many modern farms, these tasks are often done using an array of specialized (and expensive) equipment. This puts many small-scale farmers, especially those in developing countries, under significant financial pressure. These challenges led a South African engineering firm to develop the Kotonki, a low-cost hydraulically powered utility vehicle that can be customized for a wide variety of use cases. Video after the break.
The name Kotonki is derived from the Setswana phrase for a donkey kart. It is in essence a self-propelled hydraulic power pack, capable of hauling 1 ton of anything that can fit on its load bed. It comes in front-wheel drive or four-wheel drive versions, with each wheel individually driven by a hydraulic motor. The simple welded steel frame articulates around a double pivot, which allows it to keep all 4 wheels on the ground over any terrain. At a max speed of 10 km/h it won’t win any races, but neither would most other agricultural vehicles. The Kotonki is built mostly using off-the-shelf components and is powered by a common 12HP Honda engine. In the world of DRM agricultural equipment, this makes for simple repairs, low running costs, and easy customization for the task at hand. This can include mounting log splitters, water pumps, lifting beds, or anything else that can be driven by its hydraulic and rotary PTOs (Power Take-Off).
It’s fair to say that there’s really no phase of spaceflight that could be considered easy. But the case could be made that the most difficult part of a spacecraft’s journey is right at the very beginning, within the first few minutes of flight. At this point the vehicle’s booster rocket will be fighting with all its might against its own immense propellant-laden mass, a battle that it’s been engineered to win by the smallest of margins. Assuming the balance was struck properly and the vehicle makes its way off of the launch pad, it will still need to contend with the thick sea-level atmosphere as it accelerates, a building dynamic pressure that culminates with a point known as “Max q” — the moment where the air density imposes the maximum structural load on the rocket before quickly dropping off as the vehicle continues to ascend and the atmosphere thins.
Air-launched rockets avoid flying through dense sea level air.
While the vast majority of rocket launches have to contend with the realities of flying through the lower atmosphere, there are some exceptions. By launching a rocket from an aircraft, it can avoid having to power itself up from sea level. This allows the rocket to be smaller and lighter, as it doesn’t require as much propellant nor do its engines need to be as powerful.
The downside of this approach however is that even a relatively small rocket needs a very large aircraft to carry it. For example, Virgin Orbit’s LauncherOne rocket must be carried to launch altitude by a Boeing 747-400 airliner in order to place a 500 kg (1,100 lb) payload into orbit.
But what if there was another way? What if you could get all the benefits of starting your rocket from a higher altitude, without the cost and logistical issues involved in carrying it with a massive airplane? It might sound impossible, but the answer is actually quite simple…all you have to do it throw it hard enough.
Where today we talk broadly of climate change and it’s various effects, the conversation was once simpler. We called it “global warming” and fretted about cooking outside in the summer and the sea level rise that would claim so many of our favorite cities.
Scientists are now concerned that sea level rises could be locked in, as ice sheets and glaciers pass “tipping points” beyond which their loss cannot be stopped. Research is ongoing to determine how best we can avoid these points of no return.
At 8.4 kg, it needs a powerful motion platform to move it. [Dr. D-Flo] went with a stationary bed design, with the extruder pushed around by seven high torque NEMA23 motors on a large gantry built from C-beam aluminum extrusions. A machine this size needs to be very rigid with well-fitting parts, so [Dr. D-Flo] made heavy use of CNC machined aluminum parts.
