3D Cocooner (3D Lattice Printer)

Sometimes it feels like we haven’t yet tapped into all the possibilities of additive manufacturing. Festo, a company that loves to try innovative things (and not always bring them to market), just came up with something called the 3D Cocooner — essentially, a rostock style 3D printer on its side, with a UV cure feature to allow it to build up skeletal structures and lattice style shapes.

Similar to the MX3D-Metal 3D printer (which is currently on a mission to build a bridge end-to-end — by itself), this 3D printer specializes in printing structures as opposed to the more traditional layer approach. It’s called the 3D Cocooner as it is a bionic technology platform designed to “spin” complex lattices, very similar to naturally occurring structures.

The cool thing is, it’s not actually using plastic filament like most printers — it’s actually printing using string! The string is covered with a special UV resin which is then hardened into place as soon as it is expelled from the print head — making this more like a giant robot spider than a 3D printer.

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MDF as a mold master. It works, but nowhere near as well as tooling board.

Materials To Know: Medium Density Fiberboard

MDF is the cheapest and flattest wood you can buy at local hardware stores. It’s uniform in thickness, and easy to work with. It’s no wonder that it shows up in a lot of projects. MDF stands for Medium Density Fiberboard. It’s made by pressing materials together along with some steam, typically wood, fibers and glue. This bonds the fibers very tightly. Sometimes MDF is constructed much like plywood. Thinner layers of MDF will be made. Then those layers will be laminated together under glue and steam.The laminated MDF is not as good as the monolithic kind. It tends to tear and break out along the layers, but it’s hard to tell which kind you will get.

Proper way to attatch a fastener to MDF.
Proper way to attatch a fastener to MDF.

MDF is great, but it has a few properties to watch for. First, MDF is very weak in bending and tension. It has a Modulus of Elasticity that’s about half of plywood. Due to its structure, short interlocking fibers bound together by glue and pressure, it doesn’t take a lot to cause a crack, and then, quickly, a break. If you’d like to test this, take a sheet of MDF, cut it with a knife, flip it over, and hit the sheet right behind your cut. Chances are the MDF will split surprisingly easily right at that point.

Because of the way MDF is constructed, fasteners tend to pull out of it easily. This means that you must always make sure a fastener that sees dynamic loads (say a bearing mount) goes through the MDF to the other side into a washer and bolt. MDF also tends to compress locally after a time, so even with a washer and bolt it is possible that you will see some ovaling of the holes. If you’re going to use screws, make sure they don’t experience a lot of force, also choose ones with very large threads instead of a finer pitch. Lastly, always use a pilot hole in MDF. Any particle board can split in alarming ways. For example, if you just drive a screw into MDF, it may appear to go well at first. Then it will suddenly jump back against you. This happened because the screw is compressing the fibers in front of it, causing an upward force. The only thing pressing against that force is the top layer of laminate contacting the threads. The screw then jumps out, tearing the top layer of particle board apart.

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Hackaday Invades Toronto

Next Wednesday, April 20th, Hackaday will invade Toronto.

[Sophi Kravitz] and [Michael Guilfoil] are heading north of the border to meet up with our friends at HacklabTO. They’ll be hosting a Bring A Hack meetup with drinks, snacks, and swag.

Since this is a Bring A Hack, attendees are encouraged to bring whatever project you’re working on and show it off, give a lightning talk, and pitch it to the community. [Sophi]’s last visit to Toronto brought some crazy hardware to the meetup, including a gaming glove for a Commodore 64, a demonstration of Ontario’s power plants, testing hamburgers for anything that is not beef with PCR, and analog synthesizers.

Since the Hackaday Prize is in full swing, this is an excellent opportunity to team up with fellow Torontonians for a great Prize entry, or just bounce a few ideas off people to see if your idea is feasible.

The meet and greet at the Hacklab is free, but we would request that you RSVP for the event. The event is also on Hackaday.io, just in case you’d like to chat with [Sophi] or other attendees.

The HackadayPrize2016 is Sponsored by:

Minions Turn Your Keyboard Into A Bluetooth Keyboard

Evil geniuses usually have the help of some anonymous henchmen or other accomplices, but for the rest of us these resources are usually out of reach. [Evan], on the other hand, is on his way to a helpful army of minions that will do his bidding: he recently built a USB-powered minion that turns a regular PS/2 mouse and keyboard into a Bluetooth mouse and keyboard.

[Evan] found his minion at a McDonald’s and took out essentially everything inside of it, using the minion as a case for all of the interesting bits. First he scavenged a PS/2 port from an old motherboard. An Arduino Nano is wired to an HC-05 Bluetooth chip to translate the signals from the PS/2 peripherals into Bluetooth. The HC-05 chip is a cheaper alternative to most other Bluetooth chips at around $3 vs. $40 for more traditional ones. The programming here is worth mentioning: [Evan] wrote a non-interrupt based and non-blocking PS/2 library for the Arduino that he open sourced which is the real jewel of this project.

Once all the wiring and programming is done [Evan] can turn essentially any old keyboard and mouse into something that’ll work on any modern device. He also put an NFC tag into the minion’s head so that all he has to do to connect the keyboard and mouse is to swipe his tablet or phone past the minion.

If you’re looking for an interesting case for your next project, this McDonald’s Minion toy seems to be pretty popular. PS/2 keyboards are apparently still everywhere, too, despite their obsolescence due to USB. But there are lots of other ways to get more use out of those, too.

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Most Of What You Wish You Knew About Coils Of Wire But Were Afraid To Ask

If you are a novice electronic constructor, you will become familiar with common electronic components. Resistors, capacitors, transistors, diodes, LEDs, integrated circuits. These are the fodder for countless learning projects, and will light up the breadboards of many a Raspberry Pi or Arduino owner.

There is a glaring omission in that list, the inductor. True, it’s not a component with much application in simple analogue or logic circuits, and it’s also a bit more expensive than other passive components. But this omission creates a knowledge gap with respect to inductors, a tendency for their use to be thought of as something of a black art, and a trepidation surrounding their use in kits and projects.

We think this is a shame, so here follows an introduction to inductors for the inductor novice, an attempt to demystify them and encourage you to look at them afresh if you have always steered clear of them.

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Hoverboards Are Here – If You’re Crazy Enough To Try

A new video has been stirring questions on the internet this week. It shows a test of the Flyboard Air, a device that is somewhere between a Back to the Future Hoverboard and Green Goblin’s glider. The video depicts pilot [Frank Zapata] taking off, flying around, and landing an a platform not much larger than a milk crate. Plenty of folks are calling the video a fake. After a few back of the napkin calculations though, we’re coming out to say we think it’s real. Details are few and far between, so much of the information in this article is educated guessing based upon the video.

Here’s our hypothesis: Flyboard Air is a jet powered platform with little or no built-in intelligence. Balance, stability and control are all handled by the pilot. A hand controller simply provides throttle to adjust altitude, take off, and land.

jetfeetLet’s start with the jet powered part. During the video, [Frank] looks down at his board and the water below. Between his sneakers we can see two round openings – which look a lot like jet intakes. At the end of the video, [Frank] flies over the camera. stopping the action shows a split second where four exhaust holes are visible on the bottom of the board. These jets look quite a bit like model aircraft jet engines.

We don’t know exactly which engines [Frank] is using, but as an example, the Jet-Cat P 400 RX-G packs 88 lbs of thrust into a shell less than 6 inches in diameter, weighing less than 8 lbs. Four of those engines would provide 352 lbs of thrust. That’s plenty to lift [Frank], the board, and a few gallons of Jet-A strapped to his back.

Why no built-in intelligence? Even the smallest quadcopters have gyros, accellerometers, and PID loops keeping them upright. The problem boils down to the physics of jet engines. Active stability in a fixed pitch rotary blade system requires very fast throttle response. Quadcopters have this with their brushless motors. Turbines however, have throttle lag on the order of seconds. You can’t beat physics. Accelerating 3 or 4 pounds metal from 78,000 RPM (~70% throttle) to 98,000 RPM (~100 % throttle) takes time.

flyboard1Standing on a column of uncontrolled thrust would take quite a bit of skill on the part of the pilot. As it turns out, [Frank] is one of the world’s most experienced thrust riders. His previous invention, the Flyboard uses a personal watercraft to create a column of thrust which the rider stands on. These boards have become tremendously popular at vacation spots in the last few years. There are plenty of videos on [Frank’s] YouTube channel showing the amount of control a skilled ride has over the board. Loops, spins, and other aerobatics look easy.

With that much skill under his belt, [Frank] would have no problem keeping balanced on four jet engines.

Such a skilled rider means that control wouldn’t really be needed on the board. We’re betting that the only electronics are the remote throttle control and the Engine Control Computers (ECU) needed to keep the jets running and synchronized. The two electric ducted fans on the sides of the Flyboard Air appear to be running all the time, only shutting down when [Frank] lands the board.

One final thought – taking off and landing a jet vertically is difficult. Ground effects destabilize the craft. Engines can suck in their own exhaust, stalling them. These are problems faced by the harrier jump jet and the joint strike fighter. [Frank’s ] solution is not never get too close to the ground. If you watch closely, he takes off and lands from a perforated metal platform mounted off the back of a van. The metal doesn’t reflect enough thrust to cause the Flyboard to become unstable or stall.

So is the video real? We think so. This is an amazing achievement for [Frank Zapata]. Is it practical or safe? Heck no! Nor is it cheap – those engines cost €8,845.00 each.  That said, we’d love a chance to ride the Flyboard Air – after a few hours of training on the original Flyboard of course.

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3D Printed Microscope Chamber Saves Big Bucks

Optical microscopy is over 400 years old, and in that time, it has come a long way. There are many variations of microscopes both in the selection of lenses, lighting, and other tricks to allow an instrument to coax out more information about a sample.

One proven way to increase the resolving power of a microscope is oil immersion. The sample and the lens are placed in oil that is transparent and has a high refractive index. This prevents light from refracting at the air-coverslip interface, improving the microscope’s overall performance.

The University of New South Wales has a lab that uses such a microscope. They use a special (and expensive) chamber to hold down the glass coverslip and contain the oil. The problem? At nearly $400 a pop, the chambers are a constant expense to replace, and they are not flexible enough to handle custom size requirements.

[Ben Goodnow], a first year student at the university, applied his 3D printing and laser cutting know-how to design and build a suitable chamber that costs much less and can be adapted to different projects. In addition to all the design files on GitHub, there’s also a document (PDF) that describes the design iterations and the total cost savings.

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