Retrotechtacular: Häfla Hammerforge Healed

September 2, 2015 by 13 Comments

Visit any renaissance fair across the United States this fall and you’ll undoubtedly find a blacksmith. He’ll be sweating away in a tent, pounding on a piece of glowing steel set against an anvil. While the practice of the single blacksmith endures today, high-production ‘works of days past required increasing amounts of muscle. The more tireless the muscle, the better. The manual efforts of the blacksmith were replaced by huge hammers, and the blacksmith needed only to turn the piece between impressions and maintain a healthy respect for the awesome crushing power of the machine.

Last week, blacksmith enthusiasts completed restoration work on the Häfla hammer in Finspang, Sweden. The 333 year old hydraulic hammer hadn’t been used since 1924, when operations ceased at the Häfla Hammerforge. The ‘works was built in 1682 and used the German method of forging, which had been introduced to Sweden in the 1500s. Steel production was revolutionized in the 1800s by the Bessemer process, which resulted in a much stronger product. Continue reading “Retrotechtacular: Häfla Hammerforge Healed” →

3D Objects From A Laser Cutter

September 2, 2015 by 8 Comments

Actors want to be singers and singers want to be actors. The hacker equivalent to this might be that 3D printers want to be laser cutters or CNC machines and laser cutters want to be 3D printers. When [Kurt] and [Lawrence] discovered their tech shop acquired a 120 Watt Epilog Fusion laser cutter, they started thinking if they could coax it into cutting out 3D shapes. That question led them to several experiments that were ultimately successful.

The idea was to cut away material, rotate the work piece, and cut some more in a similar way to how some laser cutters handle engraving cylindrical objects. Unlike 3D printing which is additive, this process is subtractive like a traditional machining process. The developers used wood as the base material. They wanted to use acrylic, but found that the cut away pieces tended to stick, so they continued using wood. However, the wood tends to char as it is cut.

In the end, they not only had to build special jigs and electronics, they also had to port some third party control software to solve some issues with the Epilog Fusion cutter’s built in software. The final refinement was to use the laser’s raster mode to draw surface detail on the part.

The results were better than you’d expect, and fairly distinctive looking. We’ve covered a similar process that made small chess pieces out of acrylic using two passes. This seems like a natural extension of the same idea. Of course, there are very complicated industrial machines that laser cut in three dimensions (see the video below), but they are not in the same category as the typical desktop cutter.

Continue reading “3D Objects From A Laser Cutter” →

A Tale Of Three Soldering Iron Controllers

September 2, 2015 by 33 Comments

[ZL2PD] needed to replace an old Weller soldering station and decided not to go with one of the cheap soldering stations you can find all over the Internet. He has a long story about why he had to design his own controller, but you never have to explain that to us. He kept detailed notes of his journey and in the end, he built three different controllers before settling on one.

He started with a Hakko hand piece that uses a thermistor for temperature measurements. The first iteration of the controller had analog controls. He wasn’t happy with the number of parts in the design and the simple LED display. That led him to replace the controller with an ATTiny CPU and a use a serial LCD.

Continue reading “A Tale Of Three Soldering Iron Controllers” →

How CMOS Works: Some Final Words About CMOS

September 2, 2015 by 18 Comments

Finishing up on the topic of CMOS bus logic I am going to show a couple of families with unique properties that may come in handy one day.

High Voltage Tolerant Family: AHC/AHCT

AHCT w/o high side diode
Note the missing diode to VDD

First up is a CMOS logic family  AHC/AHCT that has one of the protection diodes on the input removed.  This allows a 5V input voltage to be applied to a device powered by 3.3V so that I don’t have to add a gate just for the translation.  Any time I can translate and do it without any additional gate delays I am a happy engineer.

Of course the example above works in a single direction and bidirectional does start to get more complicated. Using a bidirectional buffer such as a 74AHCT245 will work for TTL translation when going from 3.3V back to 5V providing there is a direction control signal present.

Continue reading “How CMOS Works: Some Final Words About CMOS” →

V2V: A Safer Commute With Cars Sharing Status Updates

September 2, 2015 by 43 Comments

Every year, more than 30,000 people are killed in motor vehicle accidents in the US, and many many more are injured. Humans, in general, aren’t great drivers. Until dependable self-driving cars make their way into garages and driveways across the country, there is still a great amount of work that can be done to improve the safety of automobiles, and the best hope on the horizon is Vehicle to Vehicle communications (V2V). We keep hearing this technology mentioned in news stories, but the underlying technology is almost never discussed. So I decided to take a look at what hardware we can expect in early V2V, and the features you can expect to see when your car begins to build a social network with the others around it.

Continue reading “V2V: A Safer Commute With Cars Sharing Status Updates” →

Save WiFi: Act Now To Save WiFi From The FCC

September 2, 2015 by 152 Comments

Right now, the FCC is considering a proposal to require device manufacturers to implement security restricting the flashing of firmware. We posted something about this a few days ago, but completely missed out on a call to action. Contrary to conventional wisdom, we live under a system of participatory government, and there is still time to convince the FCC this regulation would stifle innovation, make us less secure, and set back innovation in the United States decades.

The folks at ThinkPenguin, the EFF, FSF, Software Freedom Law Center, Software Freedom Conservancy, OpenWRT, LibreCMC, Qualcomm, and other have put together the SaveWiFi campaign (archive.is capture, real link is at this overloaded server) providing you instructions on how to submit a formal complaint to the FCC regarding this proposed rule.

Under the rule proposed by the FCC, devices with radios may be required to prevent modifications to firmware. All devices operating in the 5GHz WiFi spectrum will be forced to implement security features to ensure the radios cannot be modified. While prohibiting the modification of transmitters has been a mainstay of FCC regulation for 80 years, the law of unintended consequences will inevitably show up in full force: because of the incredible integration of electronic devices, this proposed regulation may apply to everything from WiFi routers to cell phones. The proposed regulation would specifically ban router firmwares such as DD-WRT, and may go so far as to include custom firmware on your Android smartphone.

A lot is on the line. The freedom to modify devices you own is a concern, but the proposed rules prohibiting new device firmware would do much more damage. The economic impact would be dire, the security implications would be extreme, and emergency preparedness would be greatly hindered by the proposed restrictions on router firmware. The FCC is taking complaints and suggestions until September 8th.

Even if you’re not living under the jurisdiction of the FCC, consider this: manufacturers of routers and other WiFi equipment will not be selling two version of hardware, one to the US and another to the rest of the world. What the FCC regulates affects the entire world, and this proposed rule would do us all a disservice. Even if you’re not in the US, tell your second favorite websites to cover this: neither Ars Technica nor Wired have posted anything on the FCC’s proposed rule, and even boingboing is conspicuously silent on the issue. You may submit a comment until September 8th here.

Recycled Factory Recycles Soda Bottles

September 2, 2015 by 32 Comments

All over the world, mountains of polyethylene terephthalate (PET) plastics are available for recycling in the form of soda bottles. And wherever there is enough cheap raw material, a market is sure to emerge for it. One brilliant inventor in Brazil has decided to capitalize on this market by building a magnificent factory to turn PET bottles into threads, rope, and other products.

Not a word of English is spoken in the video, and our Portuguese stops at obrigado, but you don’t really need to understand what’s being said to know what’s going on. Built from what looks to be the running gear of several bicycles and motors from various cast-off appliances, our nameless genius’ machines slit the PET bottles into fine threads, winds the thread onto spools, and braids the threads into heavier cords. We love the whole home-brew vibe of the machines; especially clever is the hacked desk calculator wired to a microswitch to count revolutions, and the salvaged auto jack used to build a press for forming the broom heads. All in all it’s a pretty amazing little factory cranking out useful products from zero-cost raw material.

We’d love to have more context about what’s being said in the video, so we’ll put this one out there for our Portuguese-speaking readers. Maybe we can get a partial translation in the comments? If so, then obrigado.

[Thanks W4RIS]