When you’re building a machine that needs to be accurate, you need to give it a nice solid base. A good base can lend strength to the machine to ensure its motions are accurate, as well as aid in damping vibrations that would impede performance. The problem is, it can be difficult to find a material that is both stiff and strong, and also a good damper of vibrations. Steel? Very stiff, very strong, terrible damper. Rubber? Great damper, strength leaves something to be desired. [Adam Bender] wanted to something strong that also damped vibrations, so developed a composite epoxy machine base.
[Adam] first takes us through the theory, referring to a graph of common materials showing loss coefficient plotted against stiffness. Once the theory is understood, [Adam] sets out to create a composite material with the best of both worlds – combining an aluminium base for stiffness and strength, with epoxy composite as a damper. It’s here where [Adam] begins experimenting, mixing the epoxy with sand, gravel, iron oxide and dyes, trying to find a mixture that casts easily with a good surface finish and minimum porosity.
With a mixture chosen, it’s then a matter of assembling the final mould, coating with release agent, and pouring in the mixture. The final result is impressive and a testament to [Adam]’s experimental process.
French hacker [akila] is building up a home automation system. In particular, he’s been working with the “SmartHome” series of gadgets made by Chinese smartphone giant, Xiaomi. First, he started off by reverse-engineering their very nicely made temperature and humidity sensor. (Original in French, hit the translate button in the lower right.) With that under his belt, he opened up the PIR motion sensor unit to discover that it has the same debugging pinouts and the same processor. Almost too easy.
For a challenge, [akila] decided it was time to implement something useful in one of these gadgets: a ZigBee sniffer so that he can tell what’s going on in the rest of his home network. He built a USB/serial programming cable to work with the NXP JN5169’s bootloader, downloaded the SDK, and rolled up his sleeves to get to work.
While trolling through the SDK, he found some interesting firmware called “JennicSniffer”. Well, that was easy. There’s a demo version of a protocol analyzer that he used. It would be cool to get this working with Wireshark, but that’s a project for another day. [Akila] got far enough with the demo analyzer to discover that the packets sent by the various devices in the home network are encrypted. That’s good news for the security-conscious out there and stands as the next open item on [akila]’s to-do list.
We don’t see as many ZigBee hacks as we’d expect, but they’ve definitely got a solid niche in home automation because of commercial offerings like Philips Hue and Wink. And of course, there’s the XBee line of wireless communications modules. We just wrote up a ZigBee hack that aims to work with the Hue system, though, so maybe times are changing?
The victim donor hardware for this project is a toothbrush meant for kids called Tooth Tunes. They’ve been around for years, but unless you’re a kid (or a parent of one) you’ve never heard of them. That’s because they generally play the saccharine sounds of Hannah Montana and the Jonas Brothers which make adults choose cavities over dental health. However, we’re inclined to brush the enamel right off of our teeth if we can listen to The Amp Hour, Embedded FM, or the Spark Gap while doing so. Yes, we’re advocating for a bone-conducting, podcasting toothbrush.
[Joe’s] hack starts by cracking open the neck of the brush to cut the wires going to a transducer behind the brushes (his first attempt is ugly but the final process is clean and minimal). This allows him to pull out the guts from the sealed battery compartment in the handle. In true [Grand] fashion he rolled a replacement PCB that fits in the original footprint, adding an SD card and replacing the original microcontroller with an ATtiny85. He goes the extra mile of making this hack a polished work by also designing in an On/Off controller (MAX16054) which delivers the tiny standby current needed to prevent the batteries from going flat in the medicine cabinet.
Check out his video showcasing the hack below. You don’t get an audio demo because you have to press the thing against the bones in your skull to hear it. The OEM meant for this to press against your teeth, but now we want to play with them for our own hacks. Baseball cap headphones via bone conduction? Maybe.
Update: [Joe] wrote in to tell us he published a demonstration of the audio. It uses a metal box as a sounding chamber in place of the bones in our head.
In the comments to our recent article about Wimshurst machines, we saw that some hackers had never heard of them, reminding us that we all have different backgrounds and much to share. Well here’s one I’m guessing even fewer will have heard of. It’s never even shown up in a single Hackaday article, something that was also pointed out in a comment to that Wimshurst article. It is the Lord Kelvin’s Water Dropper aka Lord Kelvin’s Thunderstorm, invented in the 1860s by William Thomson, 1st Baron Kelvin, the same fellow for whom the Kelvin temperature scale is named. It’s a device that produces a high voltage and sparks from falling drops of water.
The Midwest RepRap Festival is the best place to go if you want to see the latest in desktop 3D printing. This weekend, we saw full-color 3D printers, a printer with an infinite build volume, new extruders, a fantastic development in the pursuit of Open Source filament, and a whole bunch of D-bots. If you want the bleeding edge in 3D printing, you’re going to Goshen, Indiana.
Of course, it wasn’t always like this. In 2009, MakerBot released the Cupcake, a tiny printer that ushered in the era of democratized 3D printing. The Cupcake was a primitive machine, but it existed, it was open source, and it was cheap – under $500 if you bought it at the right time. This was the printer that brought customized plastic parts to the masses, and even today no hackerspace is complete without an unused Cupcake or Thing-O-Matic sitting in the corner.
The MakerBot Cupcake has not aged well. This should be expected for a technology that is advancing as quickly as 3D printing, but today it’s rare to see a working first generation MakerBot. Not only was the Cupcake limited by the technology available to hackers in 2009, there are some pretty poor design choices in these printers. There’s a reason that old plywood MakerBot in your hackerspace isn’t used anymore – it’s probably broken.
This year at MRRF, [Ryan Branch] of River City Labs brought out his space’s MakerBot Cupcake, serial number 1515 of 2,625 total Cupcakes ever made. He got his Cupcake to print a test cube. If you’re at all familiar with the Cupcake, yes, this is a hack. It’s a miracle these things ever worked in the first place.
The nuclear age changed steel, and for decades we had to pay the price for it. The first tests of the atomic bomb were a milestone in many ways, and have left a mark in history and in the surface of the Earth. The level of background radiation in the air increased, and this had an effect on the production of steel, so that steel produced since 1945 has had elevated levels of radioactivity. This can be a problem for sensitive instruments, so there was a demand for steel called low background steel, which was made before the trinity tests.
The Bessemer process pumps air through the iron to remove impurities. shropshirehistory.com
The production of steel is done with the Bessemer process, which takes the molten pig iron and blasts air through it. By pumping air through the steel, the oxygen reacts with impurities and oxidizes, and the impurities are drawn out either as gas or slag, which is then skimmed off. The problem is that the atmospheric air has radioactive impurities of its own, which are deposited into the steel, yielding a slightly radioactive material. Since the late 1960s steel production uses a slightly modified technique called the BOS, or Basic Oxygen Steelmaking, in which pure oxygen is pumped through the iron. This is better, but radioactive material can still slip through. In particular, we’re interested in cobalt, which dissolves very easily in steel, so it isn’t as affected by the Bessemer or BOS methods. Sometimes cobalt is intentionally added to steel, though not the radioactive isotope, and only for very specialized purposes.
Recycling is another reason that modern steel stays radioactive. We’ve been great about recycling steel, but the downside is that some of those impurities stick around.
Why Do We Need Low Background Steel?
Imagine you have a sensor that needs to be extremely sensitive to low levels of radiation. This could be Geiger counters, medical devices, or vehicles destined for space exploration. If they have a container that is slightly radioactive it creates an unacceptable noise floor. That’s where Low Background Steel comes in.
A person is placed into a low background steel container with sensitive equipment to measure the radioactivity of the body, which may be near the background level. Photo from orau.org
So where do you get steel, which is a man-made material, that was made before 1945? Primarily from the ocean, in sunken ships from WWII. They weren’t exposed to the atomic age air when they were made, and haven’t been recycled and mixed with newer radioactive steel. We literally cut the ships apart underwater, scrape off the barnacles, and reuse the steel.
Fortunately, this is a problem that’s going away on its own, so the headline is really only appropriate as a great reference to a popular movie. After 1975, testing moved underground, reducing, but not eliminating, the amount of radiation pumped into the air. Since various treaties ending the testing of nuclear weapons, and thanks to the short half-life of some of the radioactive isotopes, the background radiation in the air has been decreasing. Cobalt-60 has a half-life of 5.26 years, which means that steel is getting less and less radioactive on its own (Cobalt-60 from 1945 would now be at .008% of original levels). The newer BOS technique exposes the steel to fewer impurities from the air, too. Eventually the need for special low background steel will be just a memory.
Oddly enough, steel isn’t the only thing that we’ve dragged from the bottom of the ocean. Ancient Roman lead has also had a part in modern sensing.
You will all no doubt be familiar with the 74 series logic integrated circuits, they provide the glue logic for countless projects. If you look back through old listings of the series you’ll find alongside the familiar simple gates a host of now obsolete chips that reveal their roots in the pre-microprocessor computer industry of the late 1960s, implementing entire functions that would now be integrated.
One of the more famous of these devices is the 74181, a cascadable 4-bit arithmetic logic unit, or ALU. An ALU is the heart of a microprocessor, performing its operations. The 74181 appeared in many late-60s and early-70s minicomputers, will be familiar to generations of EE and CS students as the device they were taught about ALUs on, and can now be found in some home-built retrocomputers.
[Ken Shirriff], doyen of the integrated circuit teardown, has published a piece taking a look at the 74181, in particular at its logic functions and the reason for some of them that are rather surprising. As well as the normal logic functions, for example the chip can do “(A + B) PLUS AB“. Why on earth you might think would an ALU need to do that?
The answer lies in the way it performs carrying while adding, a significant speed-up can be achieved over ripple carrying along a chain of adders if it can be ascertained whether a bit addition might generate a carry bit. He explains the function required to perform this operation, and suddenly the unusual extra function makes sense. Addition is transformed from a serial process to a parallel one, with a consequent speed increase.
It’s one of those moments in which you have to salute those logic designers from an era when on-chip real-estate was costly and every ounce of speed had to be teased from their designs. Give it a read, and have a go at the interactive 74181 simulator further down [Ken]’s page. We learned something from the article, and so may you.
Fortunately, this is a problem that’s going away on its own, so the headline is really only appropriate as a great reference to a 
