How Advanced Autopilots Make Airplanes Safer When Humans Go AWOL

January 6, 2026 by 21 Comments

It’s a cliché in movies that whenever an airplane’s pilots are incapacitated, some distraught crew member queries the self-loading freight if any of them know how to fly a plane. For small airplanes we picture a hapless passenger taking over the controls so that a heroic traffic controller can talk them through the landing procedure and save the day.

Back in reality, there have been zero cases of large airliners being controlled by passengers in this fashion, while it has happened a few times in small craft, but with variable results. And in each of these cases, another person in the two- to six-seater aircraft was present to take over from the pilot, which may not always be the case.

To provide a more reliable backup, a range of automated systems have been proposed and implemented. Recently, the Garmin Emergency Autoland system got  its first real use: the Beechcraft B200 Super King Air landed safely with two conscious pilots on board, but they let the Autoland do it’s thing due to the “complexity” of the situation.

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A bed of metal powder is visible through a green-tinted window. A fused metal pattern, roughly square, is visible, with one corner glowing white and throwing up sparks.

Printing In Metal With DIY SLM

January 3, 2026 by 5 Comments

An accessible 3D printer for metals has been the holy grail of amateur printer builders since at least the beginning of the RepRap project, but as tends to be the case with holy grails, it’s proven stubbornly elusive. If you have the resources to build it, though, it’s possible to replicate the professional approach with a selective laser melting (SLM) printer, such as the one [Travis Mitchell] built (this is a playlist of nine videos, but if you want to see the final results, the last video is embedded below).

Most of the playlist shows the process of physically constructing the machine, with only the last two videos getting into testing. The heart of the printer is a 500 Watt fiber laser and a galvo scan head, which account for most of the cost of the final machine. The print chamber has to be purged of oxygen with shielding gas, so [Travis] minimized the volume to reduce the amount of argon needed. The scan head therefore isn’t located in the chamber, but shines down into it through a window in the chamber’s roof. A set of repurposed industrial servo motors raises and lowers the two pistons which form the build plate and powder dispenser, and another servo drives the recoater blade which smooths on another layer of metal powder after each layer.

As with any 3D printer, getting good first-layer adhesion proved troublesome, since too much power caused the powder to melt and clump together, and too little could result in incomplete fusion. Making sure the laser was in focus improved things significantly, though heat management and consequent warping remained a challenge. The recoater blade was originally made out of printed plastic, with a silicone cord along the edge. Scraping along hot fused metal in the early tests damaged it, so [Travis] replaced it with a stainless steel blade, which gave much more consistent performance. The final results looked extremely promising, though [Travis] notes that there is still room for redesign and improvement.

This printer joins the very few other DIY SLM machines we’ve seen, though there is an amazingly broad range of other creative ideas for homemade metal printers, from electrochemical printers to those that use precise powder placement.

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Testing 8 Solder Flux Pastes After Flux Killed A GeForce2 GTS

December 20, 2025 by 18 Comments
Riesba NC-559-ASM flux being applied. (Credit: Bits und Bolts, YouTube)
Riesba NC-559-ASM flux being applied. (Credit: Bits und Bolts, YouTube)

Flux is one of those things that you cannot really use too much of during soldering, as it is essential for cleaning the surface and keeping oxygen out, but as [Bits und Bolts] recently found, not all flux is made the same. After ordering the same fake Amtech flux from the same AliExpress store, he found that the latest batch didn’t work quite the same, resulting in a Geforce 2 GTS chip getting cooked while trying to reball the chip with uncooperative flux.

Although it’s easy to put this down to a ‘skill issue’, the subsequent test of eight different flux pastes ordered from both AliExpress and Amazon, including — presumably genuine — Mechanic flux pastes with reballing a section of a BGA chip, showed quite different flux characteristics, as you can see in the video below. Although all of these are fairly tacky flux pastes, with some, the solder balls snapped easily into place and gained a nice sheen afterwards, while others formed bridges and left a pockmarked surface that’s indicative of oxygen getting past the flux barrier.

Not all flux pastes are made the same, which also translates into how easy the flux remnants are to clean up. So-called ‘no clean’ flux pastes are popular, which take little more than some IPA to do the cleaning, rather than specialized PCB cleaners as with the used Mechanic flux. Although the results of these findings are up for debate, it can probably be said that ordering clearly faked brand flux paste is a terrible idea. While the top runner brand Riesba probably doesn’t ring any bells, it might be just a Chinese brand name that doesn’t have a Western presence.

As always, caveat emptor, and be sure to read those product datasheets. If your flux product doesn’t come with a datasheet, that would be your first major red flag. Why do we need flux? Find out.

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The PediSedate: A Winning Combination Of Video Games And Anesthesia

December 17, 2025 by 19 Comments
One can understand that it would be nice to have something to focus on while trying to remain calm ahead of a medical procedure. Credit: PediSedate

Once upon a time, surgery was done on patients who were fully conscious and awake. As you might imagine, this was a nasty experience for all involved, and particularly the patients. Eventually, medical science developed the techniques of anaesthesia, which allowed patients to undergo surgery without feeling pain or even being conscious of it at all.

Adults are typically comfortable in the medical environment and tolerate anaesthesia well. For children, though, the experience can be altogether more daunting. Thus was invented the PediSedate—a device which was marketed almost like a Game Boy accessory intended to deliver anaesthetic treatment in order to safely and effectively prepare children for surgery.

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The Lethal Danger Of Combining Welding And Brake Cleaner

December 17, 2025 by 57 Comments

With the availability of increasingly cheaper equipment, welding has become far more accessible these days. While this is definitely a plus, it also comes with the elephant-sized asterisk that as with any tool you absolutely must take into account basic safety precautions for yourself and others. This extends to the way you prepare metal for welding, with [Dr. Bernard], AKA [ChubbyEmu] recently joining forces with [styropyro] to highlight the risks of cleaning metal with brake cleaner prior to welding.

Much like with common household chemicals used for cleaning, such as bleach and ammonia, improper use of these can produce e.g. chlorine gas, which while harmful is generally not lethal. Things get much more serious with brake cleaner, containing tetrachloroethylene. As explained in the video, getting brake cleaner on a rusty part to clean it and then exposing it to the intensive energies of the welding process suffices to create phosgene.

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How Big Is Your Video Again? Square Vs Rectangular Pixels

December 8, 2025 by 11 Comments

[Alexwlchan] noticed something funny. He knew that not putting a size for a video embedded in a web page would cause his page to jump around after the video loaded. So he put the right numbers in. But with some videos, the page would still refresh its layout. He learned that not all video sizes are equal and not all pixels are square.

For a variety of reasons, some videos have pixels that are rectangular, and it is up to your software to take this into account. For example, when he put one of the suspect videos into QuickTime Player, it showed the resolution was 1920×1080 (1350×1080). That’s the non-square pixel.

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Ore Formation: A Surface Level Look

December 4, 2025 by 9 Comments

The past few months, we’ve been giving you a quick rundown of the various ways ores form underground; now the time has come to bring that surface-level understanding to surface-level processes.

Strictly speaking, we’ve already seen one: sulfide melt deposits are associated with flood basalts and meteorite impacts, which absolutely are happening on-surface. They’re totally an igneous process, though, and so were presented in the article on magmatic ore processes.

For the most part, you can think of the various hydrothermal ore formation processes as being metamorphic in nature. That is, the fluids are causing alteration to existing rock formations; this is especially true of skarns.

There’s a third leg to that rock tripod, though: igneous, metamorphic, and sedimentary. Are there sedimentary rocks that happen to be ores? You betcha! In fact, one sedimentary process holds the most valuable ores on Earth– and as usual, it’s not likely to be restricted to this planet alone. Continue reading “Ore Formation: A Surface Level Look” →