Hacking Balsa To Make It Stronger

Balsa wood has long been revered for its strength and lightweight composition, two properties that make it ideal for building model structures and airplanes. Researchers from the US and China have managed to make balsa even stronger and more useful. They’ve found a way to change its structure, turning it into a carbon sponge that’s strong enough to withstand repeated mechanical strain, but light enough to sit atop a dandelion gone to seed.

Using common chemicals like lye and hydrogen peroxide, the scientists burned the hemicellulose and lignin fibers that make up balsa’s rectangular cell walls. Then they incinerated the sample at 1,000°C, which morphed the cellular structure into a cross between a helical spring and a honeycomb.

Normally, carbonized wood just collapses under weight. But by first burning the cell fibers, the carbonization process results in a balsa carbon sponge capable of withstanding thousands of compressions before deforming. The researchers used the new material as part of a mechanical strain sensor prototype for wearable electronics, and they see a solid future for the material in water purification devices, supercapacitors, and rechargeable batteries.

This is big news for a society that’s trying to find more environmentally responsible ways to keep going full steam ahead in technological growth. Balsa trees grow fast, averaging 10+ feet per year, so this is a more sustainable alternative to graphene and carbon nanotubes. We’re excited to see what comes of this hack of nature. You can read the full paper here.

Even in its natural state, balsa is an interesting material. We once saw someone exploit its water retention abilities to make a rain-activated, shape-shifting prototype for roofing shingles.

Thanks for the tip, [Gervais].

Not Just Your Average DIY Spot Welder

Microwave oven transformer spot welder builds are about as common as Nixie tube clocks around here. But this spot welder is anything but common, and it has some great lessons about manufacturing techniques and how to achieve a next level look.

Far warning that [Mark Presling] has devoted no fewer than five videos to this build. You can find a playlist on his YouTube channel, and every one of them is well worth the time. The videos covering the meat of what went into this thing of beauty are below. The guts are pretty much what you expect from a spot welder — rewound MOT and a pulse timer — but the real treat is the metalwork. All the very robust parts for the jaws of the welder were sand cast in aluminum using 3D-printed patterns, machined to final dimensions, and powder coated. [Mark] gives an excellent primer on creating patterns in CAD, including how to compensate for shrinkage and make allowance for draft. There are tons of tips to glean from these videos, and plenty of inspiration for anyone looking to achieve a professional fit and finish.

In the category of Best Appearing Spot Welder, we’ll give this one the nod. Runners-up from recent years include this plastic case model and this free-standing semi-lethal unit.

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Customizing STLs For Off-Brand Devices

[Rob Clarke] needed a mount for his off-brand action camera, but it’s not exactly the kind of thing with a bustling accessory market. To make matters worse, it turns out the camera is so low-key that he couldn’t find a 3D printable mount for it either. Luckily, a check with his calipers confirmed his camera is just about the same size as an old GoPro Hero 3, so all he had to do was modify an existing design to fit his needs.

As anyone who’s worked with STL files will tell you, they are a pain to modify. An STL is essentially a completed solid model, and not really meant to be fiddled around with. It’s a bit like trying to take an edited image and get back to the layers that were used to create it in Photoshop or GIMP. The final output has been “flattened”, so that granular control is lost.

That being said, [Rob] got rather lucky in this case. He found a GoPro mount that was about 90% there, he just needed to adjust the depth and change the positioning of the holes on the side. He loaded the STL into SketchUp, deleted the two sides, and replaced them with new surfaces. This gave him a clean slate to add the appropriate openings for his camera’s USB port and microSD card. To adjust the depth of the mount, he simply stretched the model out on the Z axis.

[Rob] event went ahead and released his modified STLs as a remix of the original case he found on Thingiverse for anyone else that has the same camera. That’s what we love to see.

If you’re interested in learning more about using SketchUp for designing 3D printed parts, check out this excellent guide by our very own [Brian Benchoff].

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Evolution Of The Worlds Oldest Computer Festival

The Trenton Computer Festival (TCF) doesn’t have the name recognition of big technology conferences like DEF CON or HOPE. It’s not even as well known as smaller more localized conferences like DerbyCon, ShmooCon, or the Hackaday Superconference. In fact, there’s a good chance that most readers have never even heard of TCF. But despite not holding a place in the hacker lexicon, TCF has plenty to boast about. Its played host to technology luminaries from Bill Gates to Richard Stallman, and now in its 43rd year, holds the title as the longest continually running technology festival in the world.

Bill Gates giving the keynote at TCF in 1989

When originally conceived in 1976, the show was devoted to the dawning age of the personal computer, but since then has evolved into a celebration of technology as a whole. When TCF kicks off on March 17th, there won’t be a media blitz or huge corporate sponsorship. There won’t be a simultaneous online stream of the event, and the only badges worn by speakers or attendees will be of the paper variety.

What you will find at TCF is a full schedule of talks given by people who are passionate about technology in its varied forms. These run the gamut from quantum computing to lock picking, from Arduino to Space Shuttle avionics.

At the heart of TCF is co-founder and current Chair Dr Allen Katz. I recently had the opportunity to speak with Dr Katz about the challenges of running a conference of this type, and the secret to keeping relevant in a wildly changing technology landscape.

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Friday Hack Chat: Everything About The ESP

When the ESP-8266 first arrived, it was a marvel. For two dollars, you could buy a simple module that could serve as a bridge between WiFi networks and microcontroller projects. It understood the Hayes command set, it didn’t use much power, and, as noted before, it only cost two dollars. The idea of cheap and accessible Internet of Things things was right there for the taking.

Then hackers figured out what was actually going on inside the ESP-8266. It was a full-blown microcontroller. There was Lua stuff you could put on it. You could program it with the Arduino IDE. It had WiFi. This was the greatest microcontroller release in the last decade, and it came from a company no one had ever heard of.

Since then, the ESP ecosystem has bloomed, and there’s a new ESP on the block. The ESP-32 is an even more powerful WiFi and Bluetooth-enabled chip that’s just as easy to program, and it costs three dollars. Microcontrollers have never been cooler.

For this week’s Hack Chat, we’re going to be talking all about the ESP. Our guest for this Hack Chat should need no introduction, but if you’re unfamiliar, [Sprite_tm] plays video games on his keyboard and has installed Linux on a hard drive. He also works at Espressif, the company behind the ESP-8266 and ESP-32, where he’s applied his skills towards tiny Game Boys and miniature Macs.

During this week’s Hack Chat, we’re going to be covering everything about the ESP, including peripherals, ultra-low power consumption, SIP packages, and what’s coming up for the ESP family. You are, as always, welcome to submit your questions for [Sprite]; just add those as a comment on the Hack Chat page.

join-hack-chat

Our Hack Chats are live community events on the Hackaday.io Hack Chat group messaging. [Sprite]’s in China, so we’re not doing this one at the usual time: This week, the Hack Chat will happen at 7:00 am, Pacific, Friday, March 9th. Want to know what time this is happening in your neck of the woods? Have a countdown timer!

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io.

You don’t have to wait until Friday; join whenever you want and you can see what the community is talking about.

Detoured: Inside MachineHistories

When designers and architects need a fancy centerpiece, a design element, or even some wall sconces, they don’t head over to the machine shop by themselves. They get someone else, who owns some fancy machines, knows how to use those fancy machines, and can create anything out of wood, foam, or metal to do the fabrication for them. Think of these companies as artisan contractors, capable of turning whatever an architect thinks of into a real, tangible object.

One of these such companies is MachineHistories, a joint venture between [Steven Joyner] and [Jason Pilarsky], who work in the medium of computer code and CNC programming. As part of the SupplyFrame Design Lab’s Detoured series, lead Staff Designer [Majenta Strongheart] takes us along for a tour of MachineHistories to figure out how this collaboration actually works.

This collaboration began at the ArtCenter College of Design where [Steven] and [Jason] spent most of their time working in the shop. Eventually, they realized they didn’t actually need the ArtCenter and decided to sign a lease and strike out on their own. The first tools in their new shop were just a 3-axis CNC and a laser cutter, but MachineHistories gradually expanded to enormous five-axis machines and other incredible tools. These machines are put to work creating works of art for architectural and design installations, ranging from futuristic chairs, fine furniture, to sculptures and even new designs for simple home items.

The skill and craftsmanship that goes into these works of art are beyond compare, but this is a great insight into how all those manufactured panels, design elements, and artistic accents are created, and one that shows you can do anything, provided you have the right tools.

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A Bit More Than A Microphone: The Electret Story

When designing a microphone assembly the other day, I reached for an electret condenser microphone capsule without thinking. To be strictly accurate I ordered a pack of them, these small cylindrical microphones are of extremely high quality for their relatively tiny price.

It was only upon submitting the order that I had a thought for the first time in my life: Just what IS an electret condenser microphone?

A condenser microphone is easy enough to explain. It’s a capacitor formed from a very thin conductive sheet that functions as the diaphragm, mounted in front of another conductor, usually a piece of mesh. Sound waves cause the diaphragm to vibrate, and these vibrations change the capacitance between diaphragm and mesh.

If that capacitance is incorporated into an RC circuit with a very high impedance and a high voltage is applied, a near constant charge is placed upon it. Since the charge stays constant, changing the capacitance causes a tiny voltage fluctuation that can be retrieved as the audio signal from the microphone. Condenser microphones built in this way can be extremely high quality, but come at the expense of needing a high voltage power supply to supply the charge and an amplifier to buffer and magnify the audio.

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