DIY Injection Mold Design For The Home Shop

3D printing is great for prototyping, and not bad for limited runs of parts. Unfortunately though it really doesn’t scale well beyond a few pieces, so when you’re ready for the mass market you will need to think about injection molding your parts. But something like that has to be farmed out, right? Maybe not, if you know a thing or two about designing your own injection molds.

The video below comes from [Dave Hakkens] by way of his Precious Plastic project, whose mission it is to put the means of plastic recycling into the hands of individuals, rather than relying on municipal programs.  We’ve covered their work before, and it looks like they’ve come quite a way to realizing that dream. This tutorial by [Dave]’s colleague [Jerry] covers the basic elements of injection mold design, starting with 3D modeling in Solidworks. [Jerry] points out the limitations of a DIY injection molding effort, including how the thickness of parts relates to injection pressure. Also important are features like gentle curves to reduce machining effort, leaving proper draft angles on sprues, and designing the part to ease release from the mold. [Jerry] and [Dave] farmed out the machining of this mold, but there’s no reason a fairly complex mold couldn’t be produced by the home gamer.

When you’re done learning about mold design, you’ll be itching to build your own injection mold machine. Precious Plastic’s tutorial looks dead simple, but this machine looks a little more capable. And why CNC your molds when you can just 3D print them?

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A Sandbox For DIY Pinball Design

If you’ve always wanted to build your own pinball machine but have no idea where to start, this is the project for you. [Chris] is in the process of building a 3/4 size pinball table and is currently in the waiting-for-parts stage. As they arrive, he is testing them in a sandbox he built in an afternoon. Let [Chris]’s proving ground be your quick-start guide to all the ways you could approach the two most important parts of any pin: the flippers and targets.

The field of play is a sturdy piece of particle board, and the cardboard walls are attached with hot glue. [Chris] designed and printed a pair of flippers that are driven by some cheap remote door lock motors he found at a popular online auction house. You can see how snappy are in the test video after the break.

We love the crisp action and elegant simplicity of the spring-loaded drop targets [Chris] designed. Right now he resets them manually, but soon they will be reset by a solenoid or maybe a motor. We can’t wait to see how the table turns out. In the meantime, we’ll have to go back to drooling over this amazing life-size 3D-printed pinball machine.

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Automating A Bowl Feeder With Arduino

Search for “bowl feeder” on Hackaday and you’ll get nothing but automated cat and dog feeders. That’s a shame, because as cool as keeping your pets fed is, vibratory bowl feeders are cooler. If you’ve seen even a few episodes of “How It’s Made” you’re likely to have seen these amazing yet simple devices, used to feed and align small parts for automated assembly. They’re mesmerizing to watch, and if you’ve ever wondered how parts like the tiny pins on a header strip are handled, it’s likely a bowl feeder.

[John] at NYC CNC is building a bowl-feeder with Arduino control, and the video below takes us on a tour of the build. Fair warning that the video is heavy on the CNC aspects of milling the collating outfeed ramp, which is to be expected from [John]’s channel. We find CNC fascinating, but if you’re not so inclined, skip ahead to the last three minutes where [John] discusses control. His outfeed ramp has a slot for an optical sensor to count parts. For safety, the Arduino controls the high-draw bowl feeder through an external relay and stops the parts when the required number have been dispensed.

We know, watching someone use a $20,000 CNC milling station might seem overkill for something that could have been 3D printed, but [John] runs a job shop after all and usually takes on big industrial jobs. Or small ones, like these neat color-infill machine badges.

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A Motion Sensing Light For Your Entrance Hallway

Arriving home to a dark house with an armful of anything is usually an exercise in fumbling confusion until someone manages to turn on a light. [Pavel Gesyuk] has circumvented this problem entirely by building and installing a motion detecting entrance light!

[Gesyuk] is using an Arduino clone by the name of  Funduino Mini Pro, a 2-channel, 2-way relay, — he only needed one, but you use what you have on hand — a recycled power supply to convert 220V AC to 5V DC, and an infrared sensor.

The project’s goal — in excess of a lighting solution for an entrance hallway — was the learn the ins and outs of the Arduino and motion sensors. After some initial hurdles familiarizing himself with the Arduino, [Gesyuk] wired everything together on a protoboard and stuck it in a plastic case — loose wires in a high traffic area doesn’t a safe home make.

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(Nearly) All Your Computers Run MINIX

Are you reading this on a machine running a GNU/Linux distribution? A Windows machine? Or perhaps an Apple OS? It doesn’t really matter, because your computer is probably running MINIX anyway.

There once was a time when microprocessors were relatively straightforward devices, capable of being understood more or less in their entirety by a single engineer without especially God-like skills. They had buses upon which hung peripherals, and for code to run on them, one of those peripherals had better supply it.

A modern high-end processor is a complex multicore marvel of technological achievement, so labyrinthine in fact that unlike those simple devices of old it may need to contain a dedicated extra core whose only job is to manage the rest of the onboard functions. Intel processors have had one for years, it’s called the Management Engine, or ME, and it has its own firmware baked into the chip. It is this firmware, that according to a discovery by [Ronald Minnich], contains a copy of the MINIX operating system.

If you are not the oldest of readers, it’s possible that you may not have heard of MINIX. Or if you have, it might be in connection with the gestation of [Linus Torvalds]’ first Linux kernel. It’s a UNIX-like operating system created in the 1980s as a teaching aid, and for a time it held a significant attraction as the closest you could get to real UNIX on some of the affordable 16-bit desktop and home computers. Amiga owners paid for copies of it on floppy disks, it was even something of an object of desire. It’s still in active development, but it’s fair to say its attraction lies in its simplicity rather than its sophistication.

It’s thus a worry to find it on the Intel ME, because in that position it lies at the most privileged level of access to your computer’s hardware. Your desktop operating system, by contrast, sees the hardware through several layers of abstraction in the name of security, so a simple OS with full networking and full hardware access represents a significant opportunity to anyone with an eye to compromising it. Placing tinfoil hats firmly on your heads as the unmistakable thwop of black helicopters eases into the soundscape you might claim that this is exactly what they want anyway. We would hope that if they wanted to compromise our PCs with a backdoor they’d do it in such a way as to make it a little less easy for The Other Lot. We suspect it’s far more likely that this is a case of the firmware being considered to be an out-of-sight piece of the hardware that nobody would concern themselves with, rather than a potential attack vector that everyone should. It would be nice to think that we’ll see some abrupt updates, but we suspect that won’t happen.

Intel I7 processor underside: smial [FAL].

ESP-Powered Nixie Clock Knows The Time

We see more than our fair share of nixie clocks here at Hackaday, and it’s nice to encounter one that packs some clever features. [VGC] designed his nixie tube clock to use minimal energy to operate: it needs only 5V via USB to work, and draws a mere 200 mA. Nixies require Soviet-approved 180v to trigger, so [VGC] used dynamic indication and a step-up voltage converter to run them, with a 74141 nixie decoder doing the heavy lifting.

The brains of the project is an ESP8266, which connects to his house’s WiFi automatically. The clock simply dials into an NTP server and sets its own time, so no RTC is needed. It also can communicate with the cloud via Telegram, allowing the clock to send alerts to [VGC]’s devices. The ESP’s firmware may likewise be updated over WiFi. The 3D-printed case and flashing second indicators are nice touches on top of the clock functionality.

As we said, everything from wrist watches to dashboard tachometers uses nixies for displays — we love those old-skool tubes!

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IceSL Is A Cool Slicer

The mechanical and electronic parts of a 3D printer are critical for success, but so is the slicing software. Slic3r and Cura are arguably the most popular, and how they command your printer has a lot to do with the results you can get. There are lots of other slicers out there both free and paid, but it is hard to really dig into each one of them to see if they are really better than whatever you are using today. If you are interested in the performance of IceSL — a free slicer for Windows and Linux — [DIY3DTECH] has a video review that can help you decide if you want to try it. You can see the video below.

IceSL has several modules and can actually do OpenSCAD-like modeling in Lua so you could — in theory — do everything in this one tool. The review, though, focuses only on the slicing aspect. In addition to the desktop client versions, you can use some features online (although on our Linux machine it didn’t work with the latest Chrome beta even with no add ons; Firefox worked great, though).

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