Quick And Easy Pressure Forming Makes Plexiglas Domes

March 22, 2016 by 29 Comments

Thermoplastics are amazingly versatile materials. Apply some heat, add a little force, and within seconds you’ve got a part. It’s not always quite that simple, but as [maxelrad] discovered, sometimes thermoforming can be as easy as blowing up a balloon.

In need of a cowling for an exterior light fixture on an experimental aircraft, [maxelrad] turned to pressure forming of Plexiglas for the hemispherical shape he needed. His DIY forming rig was a plumbing-aisle special: PVC pipe and caps, some air hose and fittings, and a toilet flange for the pressure chamber. The Plexiglas was softened in a toaster oven, clamped over the business end of the chamber, and a few puffs of air inflated the plastic to form a dome. [maxelrad] points out that a template could be applied over the plastic sheet to create the streamlined teardrop shape he needs, and he notes that the rig would likely work just as well for vacuum forming. Of course, a mold could be substituted for the template to make this a true blow-molding outfit, but that would take away from the simplicity of this solution.

There have been a fair number of thermoforming projects featured on Hackaday before, from this DIY vacuum former to a scratch-built blow molder. And while we really like the simplicity of [maxelrad]’s technique, what we’d really love to see is some details on that airplane build.

Embed With Elliot: ARM Makefile Madness

March 22, 2016 by 47 Comments

To wrap up my quick tour through the wonderland of make and makefiles, we’re going to look at a pair of possible makefiles for building ARM projects. Although I’m specifically targeting the STM32F407, the chip on a dev board that I have on my desk, it’s reasonably straightforward to extend these to any of the ST ARM chips, and only a bit more work to extend it to any ARM processor.

If you followed along in the first two installments of this series, I demonstrated some basic usages of make that heavily leveraged the built-in rules. Then, we extended these rules to cross-compile for the AVR series of microcontrollers. Now we’re going to tackle a more complicated chip, and that’s going to mean compiling with support libraries. While not required, it’s a lot easier to get an LED blinking on the ARM platforms with some additional help.

One of the main contributions of an IDE like Arduino or mbed or similar is the ease of including external libraries through pull-down menus. If you’ve never built a makefile-based project before, you might be surprised how it’s not particularly more difficult to add libraries to your project.
Continue reading “Embed With Elliot: ARM Makefile Madness” →

Electric Compass For A Plasma Cutter

March 22, 2016 by 26 Comments

If you are a Maker space or individual lucky enough to own a Plasma Cutter, this electric protractor compass could be handy. The folks over at [MakeItExtreme] built this circle cutting tool to help cut circles and rings in thick metal sheets using their plasma cutter.

The whole thing is built around an electro-magnet, so the jig will only work with magnetic metals. There are not a lot of design details, but it’s possible to infer how to build one looking at the video and the photos on their blog. There’s a couple of nice hacks along the way. Since the electro-magnet is stationary while the rest of the jig rotates, the main mounting bolt had a hole drilled through it to help route the cable. The rotating protractor arm is made from a slab of aluminium and holds all the other parts together – the drive motor, the central hub and the plasma head. The motor used appears to be a 60rpm AC synchro motor. These types usually have an RC phase shifting network between the two coils to allow direction reversal. Friction drive is used to rotate the jig, with the friction coming from a pair of rubber tube bands attached to the electro-magnet and the motor drive hub. The plasma head holder has a rod-end with a roller bearing attached, acting as a caster wheel, ensuring the arc gap is maintained as the jig rotates. A few switches to activate the electro-magnet, motor forward / reverse and plasma enable complete the setup.

Their blog, and YouTube channel has a lot of other interesting projects that they keep building. Check it out.

Continue reading “Electric Compass For A Plasma Cutter” →

Enzymes From The Deep – The Polymerase

March 22, 2016 by 46 Comments

Our bodies rely on DNA to function, it’s often described as “the secret of life”. A computer program that describes how to make a man. However inaccurate these analogies might be, DNA is fundamental to life. In order for organisms to grown and replicate they therefore need to copy their DNA.

dna-replication
DNA structure and replication

Since the discovery of its structure in 1953, the approximate method used to copy DNA has been obvious. The information in DNA is encoded in 4 nucleotides (which in their short form we call A,T,G, and C). These couple with each other in pairs, forming 2 complimentary strands that mirror each other. This structure naturally lends itself to replication. The two strands can dissociate (under heat we call this melting), and new strands form around each single stranded template.

However, this replication process can’t happen all by itself, it requires assistance. And it wasn’t until we discovered an enzyme called the DNA polymerase that we understood how this worked. In conjunction with other enzymes, double stranded DNA is unwound into 2 single strands which are replicated by the polymerase.

Continue reading “Enzymes From The Deep – The Polymerase” →

British Kids Finally Get Their Micro:Bits

March 22, 2016 by 80 Comments

The little board that has at times seemed so plagued with delays as to become the Duke Nukem Forever of small computers has finally shipped. A million or so British seventh-grade schoolchildren and their teachers will today start receiving their free BBC micro:bits.

Announced early last year, the plan was to rekindle the learning of code in schools through handing out a powerful and easy to program small computer to the students. The hope is that it will recapture the spirit of the 1980s, when school computing meant programming Acorn’s BBC Micro rather than learning how to use Microsoft Word.

Sadly the project has been delayed multiple times, the original target of last October was missed, and a revised estimate from January suggested they might ship at half-term (about four weeks ago). With only a few days to go before the Easter school holidays the kids will have to try them out at home, but at least they’re arriving.
Continue reading “British Kids Finally Get Their Micro:Bits” →

MRRF: 3D Printed 2D Paintings

March 22, 2016 by 15 Comments

3D printing is obviously best used in printing three-dimensional objects. Laser cutters, jig saws, and CNC routers are obviously well-equipped to machine flat panels with intricate shapes out of plastic sheets, plywood, or metal, but these devices have one drawback: they’re subtractive manufacturing, and 3D printers add material. What good is this? [Jason Preuss] demonstrated a very interesting 3D printing technique at this year’s Midwest RepRap Festival. He’s producing 2D paintings with a 3D printer, with results that look like something between very intricate inlay work and a paint by numbers kit.

[Jason Preuss]' multicolor 2D print. Notice the toolpaths in the reflection. Click to embiggen.
[Jason Preuss]’ multicolor 2D print. Notice the toolpaths in the reflection of the upper left hand corner. Click to embiggen.
[Jason] is using a 3D printer, a series of very specialized techniques, and a software stack that includes a half-dozen programs to print multicolor 2D scenes. This isn’t pigment, paint, dye, or ink; the artwork becomes a single piece of plastic with individual colors laid down one at a time.

The best example of [Jason]’s work is a copy of a paint by numbers scene. Here, [Jason] makes an outline of all the shapes, separates onto different layers by color, and prints each color, one layer at a time. It’s an incredibly labor-intensive process to even get models into a slicer. Actually printing the model is even more difficult. [Jason]’s paint by numbers scene uses about twelve different colors.

[Jason]'s 3D printed paint by numbers scene. About a dozen different colors were used for this print.
[Jason]’s 3D printed paint by numbers scene. About a dozen different colors were used for this print.
We’ve seen [Jason]’s work at MRRF before, including last year’s exhibition of a fantastic chocolate clock that was a 3D printed version of an old scroll saw pattern. Taking what is normally a 2D design and translating that into something that can be built with a 3D printer seems to be [Jason]’s forte, and the results are remarkable. If you don’t know what you were looking at, you would just think these art pieces are a strange industrial fabrication process. Once you look closer, you have an immediate respect for the artistry and craftsmanship that went into a sheet of plastic only a few millimeters thick and no bigger than a piece of paper.

[Jason] hasn’t documented his build process for these 2D pictures on a 3D printer quite yet. There’s a reason for that: it’s supposedly very complicated, and it’s going to take a while to get all the documentation together. Eventually, the process will be documented and a tutorial will pop up on [Jason]’s website. He’s also on Thingiverse, with a few semi-related designs available for download.

From what we’ve seen at MRRF, in the next few years, a dual extrusion printer will be a necessity. While dual extrusion won’t be able to recreate such colorful pictures, it will make the creation of these 2D plastic panels much easier, and they will surely be popular. We can’t wait to see what [Jason] comes up with next.

Arduino Nano Runs Battery Spot Welder

March 22, 2016 by 23 Comments

Soldering might look like a tempting and cheap alternative when building or repairing a battery pack, but the heat of the iron could damage the cell, and the resulting connection won’t be as good as a weld. Fortunately, though, a decent spot welder isn’t that tough to build, as [KaeptnBalu] shows us with his Arduino-controlled battery spot welder.

spot_welder_zoomWhen it comes to delivering the high currents necessary for spot welding, the Arduino Nano is not necessarily the first thing that comes to mind. But the need for a precisely controlled welding pulse makes the microcontroller a natural for this build, as long as the current handling is outsourced. In [KaeptnBalu]’s build, he lets an array of beefy MOSFETs on a separate PCB handle the welding current. The high-current wiring is particularly interesting – heavy gauge stranded wire is split in half, formed into a U, tinned, and each leg gets soldered to the MOSFET board. Welding tips are simply solid copper wire, and the whole thing is powered by a car battery, or maybe two if the job needs extra amps. The video below shows the high-quality welds the rig can produce.

Spot welders are a favorite on Hackaday, and we’ve seen both simple and complicated builds. This build hits the sweet spot of complexity and functionality, and having one on hand would open up a lot of battery-hacking possibilities.

Continue reading “Arduino Nano Runs Battery Spot Welder” →