3D Printed Heat Exchanger Uses Gyroid Infill For Cooling

October 31, 2022 by 33 Comments

3D printing allows the physical manufacturing of some unique geometries that are simply not possible with other processes. If you design around these strengths, it is possible to create parts that significantly outperform more conventional alternatives. With this in mind [Advanced Engineering Solutions] created a metal 3D printed heat exchanger that is half the size and four times the efficiency of the one it was designed to replace. Video after the break.

Gyroid infill splits an internal volume in two, perfect for heat exchangers.

Made from an aluminum alloy using a Laser Powder Bed Fusion (LPBF) machine, the heat exchanger is intended to cool transmission oil on military helicopters by using fuel as the coolant. Looking somewhat similar to a Fabergé egg, it uses gyroid “infill” for the actual heat exchange part. An interesting characteristic of gyroids is that it creates two separate intermeshed volumes, making them perfect for this application.

It was printed in one piece, without any removable support, just an internal lattice that supports the gyroids at the inlet and outlets. The only post-processing required was threading and surface cleanup on the ports. Since metal 3D printing is still too expensive to really allow many iterative prints, a significant amount of design and simulation time was put in before the first print.

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Stop Silicone Cure Inhibition, No Fancy Or Expensive Products Required

October 30, 2022 by 16 Comments

Casting parts in silicone is great, and 3D printing in resin is fantastic for making clean shapes, so it’s natural for an enterprising hacker to want to put the two together: 3D print the mold, pour in the silicone, receive parts! But silicone’s curing process can be inhibited by impurities. What’s cure inhibition? It’s a gross mess as shown in the image above, that’s what it is. Sadly, SLA-printed resin molds are notorious for causing exactly that. What’s a hacker to do?

Firstly: there are tin-cure and platinum-cure silicones, and for the most part tin-cure silicone works just fine in resin-printed molds. Platinum-cure silicones have better properties, but are much more susceptible to cure inhibition. Most workarounds rely on adding some kind of barrier coating to molds, but [Jan Mrázek] has a cheap and scalable method of avoiding this issue that we haven’t seen before. Continue reading “Stop Silicone Cure Inhibition, No Fancy Or Expensive Products Required” →

Garmin HUD Got Discontinued, But Not Trashed

October 30, 2022 by 8 Comments

The Garmin HUD+ was a small Bluetooth device intended for the dashboard of a car, meant to be used as a GPS heads-up display for data from Garmin smartphone apps. It used a bright VFD (vacuum fluorescent display) which was viewed through a clear reflector, and displayed GPS information and directions. It was discontinued in 2015, but [Doz] was fond of his and used it happily until a phone upgrade meant it no longer worked. Was it destined for a landfill? Not if he had anything to say about it!

The first thing [Doz] tried was using an alternate Android app, but since it also didn’t work, it was time to sit back and reflect on the scope of the issue. In [Doz]’s case, he really only wanted some basic meaningful data displayed, and decided he could do away with the phone altogether if he had the right hardware. Continue reading “Garmin HUD Got Discontinued, But Not Trashed” →

A terminal window with a search for "Guineau Pig Olympics" is inset on a photo of an ortholinear keyboard attached by a yellow USB cable to a 70s aluminum and plastic Super 8 film editor/viewer. The device has a large screen on the right hand side, a silver grate on the left, and a tray at the bottom for slotting in film.

Super 8 Film Editor Reborn As A YouTube Terminal

October 30, 2022 by 14 Comments

We love hacks that give new life to old gadgets, and [edwardianpug]’s YouTube Terminal certainly fits the bill by putting new hardware inside a Super 8 film editor.

[edwardianpug] could have relegated this classy-looking piece of A/V history to a shelf for display, but instead she decided to refresh its components so it could display any YouTube video instead of just one strip of film at a time. The Boost-Box keeps the retrofuturistic theme going by using the terminal to search for and play videos via Ytfzf.

The original screen has been replaced by an 800×600 LCD, and the yellow USB cord gives a nice splash of color to connect the ortholinear keyboard to the device. Lest you think that this “ruined” a working piece of retro-tech, [edwardianpug] says that 20 minutes would get this device back to watching old movies.

Are you looking for more modern and retro mashups? Check out these Dice Towers Built In Beautiful Retro Cases, a Vacuum Tube and Microcontroller Ham Transmitter, or this Cyberdeck in a Retro Speaker.

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All Your Pixels Are (Probably Not) Belong To Pantone

October 29, 2022 by 80 Comments

There’s a piece of news floating around the open IP and allied communities at the moment which appears to have caused some consternation. It comes from Adobe, who have announced that due to an end of their licensing deal with Pantone LLC, PSD images loaded into Photoshop will have pixels containing unlicensed Pantone colours replaced with black. What, Pantone owns colours now? Are we expected to pay a royalty every time we take a picture of a blue sky? It’s natural to react with suspicion when hearing a piece of news like this, but for once we think this might not be the unreasonable intellectual property land grab it may first appear. To illustrate this, it’s necessary to explain what Pantone does, and what they don’t do. Continue reading “All Your Pixels Are (Probably Not) Belong To Pantone” →

Welding Aluminum With A MIG Welder

October 29, 2022 by 36 Comments

Steve Martin had a bit that was like a fake infomercial where he says, “You can be a millionaire and never pay taxes!” The instructions were, “First, get a million dollars. Then,…” [Brandon’s] instructions for how to convert your MIG welder to do aluminum for under $25 is not quite like that, but you do need the right kind of MIG welder to make it work. In particular, you need an actual MIG welder that has a provision to connect external gas. The instructions show a Hobart Handler 140 that meets the criteria and has sufficient power to handle aluminum.

The main task is to replace the liner for the torch. The stock liner is steel which is fine for its intended purpose, but it is too rough for aluminum wire. A PTFE liner is inexpensive and will work fine with the aluminum wire. If you want to do normal welding later, you’ll need to put the original liner back in.

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Old CRT Television playing Luigi's Mansion on a rusted out bike (Original Photo by Anete Lusina)

Luigi’s Mansion First Person Mod Brings Spooky New Perspective

October 28, 2022 by 2 Comments

The Nintendo GameCube in many ways defied expectations. It was purple, it had buttons shaped like beans, and it didn’t launch with a Mario game. What we got instead was the horror-adjacent ghost adventure game starring Mario’s brother — Luigi’s Mansion. The game was a graphical showpiece for the time, however, the camera angles were all fixed like an early Resident Evil game. Not satisfied with playing within those bounds, modder [Sky Bluigi] created a first person camera patch for the game that finally let players see why Luigi was so freaked out all the time.

The patch dubbed Luigi’s Mansion FPO (First Person Optimized) does a lot to drive home the game’s child-friendly, spooky aesthetic. Along with the ability to explore environments with a new lens, it provides the ability to turn the flashlight on and off manually if you want. Though the most impressive part of Luigi’s Mansion FPO is that it runs on real hardware. All that’s needed to play the mod is clean image of the North American release of Luigi’s Mansion and a .xdelta patching utility like Delta Patcher. GameCube games can be ripped directly to a USB thumb drive using a soft-modded Nintendo Wii console running Clean Rip or similar backup tool.

Luigi’s Mansion FPO actually provides a collection of patches that offer revised controls and increased field of view depending on which patch is used. The original game had inverted controls for aiming Luigi’s ghost vacuum, so the “Invert C-Stick Controls” patch will install a more modern aiming scheme where up on the right stick will aim upwards and vice versa. The “Better FOV” pulls the camera a little further back from where Luigi’s head would be while the original aiming scheme is retained. Though no matter which patch you decide to go with, a mod like this is always a good excuse to revisit a cult classic.

For another fresh GameCube mod check out this post about a Raspberry Pi Pico based modchip for the system.

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