Reverse Engineering Bottle Threads For Fun And Profit

April 1, 2018 by 37 Comments

Recently, one of [Eric]’s clients asked him to design a bottle. Simple enough for a product designer, except that the client needed it to thread into a specific type of cap. And no, they don’t know the specs.

But that’s no problem, thought [Eric] as he turned on the exhaust fan and reached for the secret ingredient that would make casting the negative image of the threads a breeze. He mixed up the foul-smelling body filler with the requisite hardener and some lovely cyan toner powder and packed it into the cap with a tongue depressor. Then he capped off the cast by adding a small PVC collar to lengthen the cast so he has something to grab on to when it’s time to take it out.

Bondo does seem like a good choice for casting threads. You need something workable enough to twist out of there without breaking, but rigid enough that the small detail of the threads isn’t lost. For the release agent, [Eric] used Johnson’s Paste Wax. He notes from experience that it works particularly well with Bondo, and even seems to help it cure.

Once the Bondo hardened, [Eric] made sure it screwed in and out of the cap and then moved on to CAD modeling and 3D printing bottle prototypes until he was satisfied. We’ve got the video screwed in after the break to cap things off.

Did you know that you can also use toner powder to tint your epoxy resin? Just remember that it is particulate matter, and take precautions.

Continue reading “Reverse Engineering Bottle Threads For Fun And Profit” →

An 8-Bit ALU, Entirely From NAND Gates

March 31, 2018 by 18 Comments

One of the things that every student of digital electronics learns, is that every single logic function can be made from a combination of NAND gates. But nobody is foolhardy enough to give it a try, after all that would require a truly huge number of gates!

Someone evidently forgot to tell [Notbookies], for he has made a complete 8-bit ALU using only 4011B quad NAND gates on a set of breadboards, and in doing so has created a minor masterpiece with his wiring. It’s inspired by a series of videos from [Ben Eater] describing the construction of a computer with the so-called SAP (Simple As Possible) architecture. The 48 4011B DIP packages sit upon 8 standard breadboards, with an extra one for a set of DIP switches and LEDs, and a set of power busbar breadboards up their sides. He leaves us with the advice borne of bitter experience: “Unless your goal is building a NAND-only computer, pick the best IC for the job“.

We have covered countless processors and processor components manufactured from discrete logic chips over the years, though this makes them no less impressive a feat. The NedoNAND has been a recent example, a modular PCB-based design. TTL and CMOS logic chips made their debut over 50 years ago so you might expect there to be nothing new from that direction, however we expect this to be  well of projects that will keep flowing for may years more.

Via /r/electronics/.

3D Printed Tank Tracks

March 31, 2018 by 10 Comments

[Ivan] has been keeping his 3D printers busy with parts he’s experimenting with to build a tracked motion setup for a tank-like vehicle. His design uses several interlocking parts, so if you want to duplicate it, we hope your printer calibration is up to snuff. He’s still printing more parts and promises to release the files once the design proves out.

However, you can see he’s off to a good start. Small pieces fit together and accept a piece of filament as a sort of hinge. Some pins keep the filament from working out. Pads fit into the main parts and hold down with zip ties. The whole flexible tread locks into sprockets and a groove on a drive wheel.

Continue reading “3D Printed Tank Tracks” →

Build Your Own Antenna For Outdoor Monitoring With LoRa

March 31, 2018 by 15 Comments

LoRa and LPWANs (Low Power Wide Area Networks) are all the range (tee-hee!) in wireless these days. LoRa is a sub 1-GHz wireless technology using sophisticated signal processing and modulation techniques to achieve long-range communications.

With that simplified introduction, [Omkar Joglekar] designed his own LoRa node used for outdoor sensor monitoring based on the HopeRF RFM95 LoRa module. It’s housed in an IP68 weatherproof enclosure and features an antenna that was built from scratch using repurposed copper rods. He wrote up the complete build, materials, and description which makes it possible for others to try their hand at putting together their own complete LoRa node for outdoor monitoring applications.

Once it’s built, you can use this simple method to range test your nodes and if you get really good, you might be setting distance records like this.

Thermoelectric Generator Shines Where The Sun Doesn’t

March 31, 2018 by 81 Comments

For off-grid renewable electricity, solar seems to make sense. Just throw some PV panels on the roof and you’re all set to stick it to the man, right? But the dirty little secret of the king of clean energy is that very few places on the planet get the sort of sunshine needed to make residential PV panels worth their installation cost in the short term, and the long-term value proposition isn’t very good either.

The drearier places on the planet might benefit from this high-power thermoelectric generator (TEG) developed and tested by [TegwynTwmffat] for use on a wood burning stove. The TEG modules [Tegwyn] used are commercially available and rated at 14.4 volts and 20 watts each. He wisely started his experiments with a single module; the video below shows the development of that prototype. The bulk of the work with TEGs is keeping the cold side of the module at a low enough temperature for decent performance, since the modules work better the higher the difference in temperature is across the module. A finned heatsink and a fan wouldn’t cut it for this application, so a water-cooled block was built to pump away the heat. A successful test led to scaling the generator up to 10 modules with a very impressive heatsink, which produced about 120 watts. Pretty good, but we wonder if some easy gains in performance would have come from using heat sink compound on the module surfaces.

Using thermal differences to generate electricity is nothing new, but a twist on the technique is getting attention lately as a potential clean energy source. And who knows? Maybe [TegwynTwmffat]’s or one of the other Hackaday Prize 2018 entries will break new ground and change the world. What’s your big idea?

Continue reading “Thermoelectric Generator Shines Where The Sun Doesn’t” →

There’s More To MIDI Than Music – How About A Light Show?

March 31, 2018 by 6 Comments

MIDI instruments and controllers are fun devices if you want to combine your interest in music and electronics in a single project. Breaking music down into standardized, digital signals can technically turn anything with a button or a sensor into a musical instrument or effect pedal. On the other hand, the receiving end of the MIDI signal is mostly overlooked.

[FuseBerry], a music connoisseur with a background in electronics and computer science, always wanted to build a custom MIDI device, but instead of an instrument, he ended up with a MIDI controlled light show in the shape of an exploded truncated icosahedron ([FuseBerry]’s effort to look up that name shouldn’t go unnoticed). He designed and 3D-printed all the individual geometric shapes, and painstakingly equipped them with LEDs from a WS2818B strip. An Arduino Uno controls those LEDS, and receives the MIDI signals through a regular 5-pin DIN MIDI connector that is attached to the Arduino’s UART interface.

The LEDs are mapped to pre-defined MIDI notes, so whenever one of them is played, and their NoteOn message is received, the LEDs light up accordingly. [FuseBerry] uses his go-to DAW to create the light patterns, but any software / device that can send MIDI messages should do the trick. In the project’s current state, the light pattern needs to be created manually, but with some adjustments to the Arduino code, that could be more automated, something along the lines of this MIDI controlled Christmas light show.

Continue reading “There’s More To MIDI Than Music – How About A Light Show?” →

You Bring It, This Blings It: Retrofitting A Hot Foil Stamping Machine

March 31, 2018 by 15 Comments

Hot foil stamping is a method often used to embellish and emboss premium print media. It’s used on things like letterhead and wedding invitations to add a touch of luxury. The operation is actually quite simple, where a custom die is heated, pressed into a heat transfer foil, and then transferred on to the print media. Some of the very first manuscripts used gold leaf embossing to decorate intricate calligraphy. You can also see it often used to decorate the sides of religious texts.

Professional foil stamping machines are often pricey and the cheaper ones you can get from eBay are usually poorly made. [Lindsay Wilson] found this out when he purchased a low-cost hot foil stamping machine that was too difficult to use reliably. It got shelved for years until he had another hot foil stamping project. This time he was prepared. He took the machine apart and robust-ified it by attaching it to a heavy-duty arbor press. He also retrofit the heating assembly with his own temperature controller to improve the accuracy for the foils he wanted to use.

Continue reading “You Bring It, This Blings It: Retrofitting A Hot Foil Stamping Machine” →