On An Aging Space Station, Air Leaks Become Routine

Anyone who’s ever owned an older car will know the feeling: the nagging worry at the back of your mind that today might be the day that something important actually stops working. Oh, it’s not the little problems that bother you: the rips in the seats, the buzz out of the rear speakers, and that slow oil leak that might have annoyed you at first, but eventually just blend into the background. So long as the car starts and can get you from point A to B, you can accept the sub-optimal performance that inevitably comes with age. Someday the day will come when you can no longer ignore the mounting issues and you’ll have to get a new vehicle, but today isn’t that day.

Looking at developments over the last few years one could argue that the International Space Station, while quite a bit more advanced and costly than the old beater parked in your driveway, is entering a similar phase of its lifecycle. The first modules of the sprawling orbital complex were launched all the way back in 1998, and had a design lifetime of just 15 years. But with no major failures and the Station’s overall condition remaining stable, both NASA and Russia’s Roscosmos space agency have agreed to several mission extensions. The current agreement will see crews living and working aboard the Station until 2030, but as recently as January, NASA and Roscosmos officials were quoted as saying a further extension isn’t out of the question.

Still, there’s no debating that the ISS isn’t in the same shape it was when construction was formally completed in 2011. A perfect case in point: the fact that the rate of air leaking out of the Russian side of the complex has recently doubled is being treated as little more than a minor annoyance, as mission planners know what the problem is and how to minimize the impact is has on Station operations.

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Reducing Seams In FDM Prints With Scarf Joint Seams

One unavoidable aspect of FDM 3D printing is that each layer consists out of one or more lines that have a beginning and an end. Where these join up, a seam is formed, which can be very noticeable if the same joint exists on successive layers. Taking a hint from woodworking, a possible solution is now being worked on that involves scarf joints. This research is covered by [Michael Laws] in a recent Teaching Tech video on YouTube, where he also details his own printing attempts with a custom 3D model, and a guide by [psiberfunk/Adam L].

The idea for a scarf joint was pitched practically simultaneously by [vgdh] on the PrusaSlicer GitHub, and [Noisyfox] on the OrcaSlicer GitHub. The basic idea follows the woodworking and metalworking version of a scarf joint, with the overlap between two discrete parts across two heavily tapered ends. As with the woodworking version, the FDM scarf joint is not a silver bullet, and with the under development OrcaSlicer builds a lot of the parameters are still being tweaked to optimize the result.

If it can be made to work, it could mean that scarf joints will soon be coming to an OrcaSlicer and PrusaSlicer release near you. Theoretically it should mean faster prints than with randomized seams as fewer print head adjustments are needed, and it may provide a smoother result. Definitely an interesting development that we hope to see come to fruition.

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Fastest FPV drone, pending official confirmation. (Credit: Luke Maximo Bell)

Got To Go Fast: The Rise Of Super-Fast FPV Drones

Generally when one considers quadcopter drones, the term ‘fast’ doesn’t come to mind, but with the rise of FPV  (First Person View) drones, they have increasingly been designed to go as fast as possible. This can be for competitive reasons, to dodge enemy fire on a battlefield, or in the case of [Luke Maximo Bell] to break the world speed record. Over the course of months he set out to design the fastest FPV drone, involving multiple prototypes, many test runs and one failed official speed run.

The components of the third FPV drone attempt, as used with the world record attempt. (Credit: Luke Maximo Bell)
The components of the third FPV drone attempt, as used with the world record attempt. (Credit: Luke Maximo Bell)

The basic design of these designed-for-speed FPV drones is more reminiscent of a rocket than a quadcopter, with the upside-down propellers  requiring the operator first lifting the drone into the air from an elevated position. After this the drone transitions into a level flight profile by rotating with the propellers pointing to the back. This gives the maximum thrust, while the body provides lift.

Although this seems simple, flying this type of drone is very hard, as it’s hard to tell what is happening, even when landing. [Luke] ended up installing a camera in the nose which can rotate to provide him with different angles. Tweaking the flight computer to deal with the control issues that occur at speeds above 300 km/h.

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Hackaday Links: March 10, 2024

We all know that we’re living in a surveillance state that would make Orwell himself shake his head, but it looks like at least one company in this space has gone a little rogue. According to reports, AI surveillance start-up Flock <<insert gratuitous “What the Flock?” joke here>> has installed at least 200 of its car-tracking cameras on public roads in South Carolina alone. That’s a serious whoopsie, especially since it’s illegal to install anything on state infrastructure without permission, which it appears Flock failed to obtain. South Carolina authorities are making a good show of being outraged about this, but it sort of rings hollow to us, especially since Flock now claims that 70% of the population (of the USA, we presume) is covered by their technology. Also, police departments across the country are in love with Flock’s service, which lets them accurately track the movements of potential suspects, which of course is everyone. No word on whether Flock will have to remove the rogue cameras, but we’re not holding our breath.

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Ford Patent Wants To Save Internal Combustion

There’s no doubt the venerable internal combustion engine is under fire. A recent patent filing from Ford claims it can dramatically reduce emissions and, if true, the technology might give classic engines a few more years of service life, according to [CarBuzz].

The patent in question centers on improving the evaporative emission system’s performance. The usual evaporative emission system stores fuel fumes in a carbon-filled canister. The canister absorbs fuel vapor when under high pressure. When the engine idles and pressure in the cylinder drops, the canister releases fumes, which are combusted with ordinary fuel/air mixture.

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Custom Mouse-Making: Clay Is The Way

For something that many of us handle all day long, it sure would be nice if mice came in more sizes and shapes, wouldn’t it? Until that day, we’ll just have to find something passable or else design and build a custom-shaped mouse from scratch like [Ben Makes Everything] did.

First, [Ben] played around with some modelling clay until he had a shape he was happy with, then took a bunch of pictures of it mounted on a piece of wood for easy manipulation and used photogrammetry to scan it in for printing after cleaning it up in Blender. About six versions later, he had the final one and was ready to move on to electronics.

That’s right, this isn’t just mouse guts in an ergonomic package. Inside is Arduino Pro Micro and a PMW 3389 optical sensor on a breakout board. [Ben] was going to use flexible 3D printed panels as mouse buttons, but then had an epiphany — why not use keyboard switches and keycaps instead? He also figured he could have two buttons per finger if he wanted, so he went with Kailh reds for the fingers and and whites in the thumb.

Speaking of the thumb, there was no room for a mouse wheel in between those comparatively huge switches, so he moved it to the the side to be thumb-operated. [Ben] got everything working, and after all this, decided to make it wireless. So he switched to an Adafruit Feather S3 and designed his first PCB for both versions. Ultimately, he found that the wireless version is kind of unreliable, so he is sticking with the wired one for now.

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Upgrading PC Cooling With Software

As computing power increases with each new iteration of processors, actual power consumption tends to increase as well. All that waste heat has to go somewhere, and while plenty of us are content to add fans and heat sinks for a passable air-cooled system there are others who prefer a liquid cooling solution of some sort. [Cal] uses a liquid cooler on his system, but when he upgraded his AMD chip to one with double the number of cores he noticed the cooling fans on the radiator were ramping quickly and often. To solve this problem he turned to Python instead of building a new cooling system.

The reason for the rapid and frequent fan cycling was that the only trigger for the cooling fans available on his particular motherboard is CPU temperature. For an air cooled system this might be fine, but a water cooled system with much more thermal mass should be better able to absorb these quick changes in CPU temperature without constantly adjusting fan speed. Using a python script set up to run as a systemd service, the control loop monitors not only the CPU temperature but also the case temperature and the temperature of the coolant, and then preferentially tries to dump heat from the CPU into the thermal mass of the water cooler before much ramping of cooling fans happens.

An additional improvement here is that the fans can run at a much lower speed, reducing dust in the computer case and also reducing noise compared to before the optimizations. The computer now reportedly runs almost silently unless it has been under load for several minutes. The script is specific to this setup but easily could be modified for other computers using liquid cooling, and using Grafana to monitor the changes can easily be done as [Cal] also demonstrates when calibrating and testing the system. On the other hand, if you prefer a more flashy cooling system as a living room centerpiece, we have you covered there as well.