Etching PCBs With A 3D Printer

March 3, 2016 by 58 Comments

With the coming of very cheap blue laser diodes, PCB fabrication has become increasingly interesting. Instead of making a photoresist, placing it over a piece of pre-sensitized copper clad board, and putting the whole assemblage under a blacklight, it’s possible to put a photomask on a board with a tiny bit of very blue light. All you need is a CNC machine. A 3D printer can be a very precise CNC machine, and when you combine these two ideas together, you can make printed circuit boards with an Ultimaker.

[Geggo] had the idea of attaching a blue laser diode to his Ultimaker to burn a few traces into presensitized copper board. With a 3D printed adapter, he was able to mount the diode and associated electronics right on the extruder body. With a small ring to tighten up the aperture, [geggo] was able to put a 50 micrometer wide dot of light on a piece of copper. The laser is powered directly from the PWM fan output on the printer controller board, allowing this entire mish-mash of cheap electronics to be controlled via G-code.

A few experiments were necessary to determine the correct speeds and power settings, with the best results being 1000 mm per minute at 40 mA. The finished board looks fantastic, and a few minutes after [geggo] was done etching a board, he started using his 3D printer as a printer. It’s a result that is so good, so easy to accomplish, and requires so little effort it makes us wonder why we don’t see more of this.

Materials To Know: Acetal And Delrin

March 3, 2016 by 65 Comments

Delrin, Acetal, and its many trade names is a material properly known as Polyoxymethylene or POM. It is one of the strongest plastics and is a good go-to material when you want the best properties of plastic, and don’t need the full strength of a metal part. It was originally formulated to compete with Zinc and Aluminum castings after all.

I won’t go too deep into the numbers behind POM. If you need the Young’s Modulus, you probably don’t need this guide. This is intended to be more of a guide to its general properties. When you’re looking for something to fit an application it is usually easier to shift through the surface properties to select a few candidates, and then break the calculator out later to make sure it will work if you’re uncertain about the factor of safety.

The most popular property of POM is its ease of machining. While doing this research every single site I came across referred to it as the most machinable plastic. That’s about as objective as subjective praise can get. It doesn’t tend to grab tools like, for example, HDPE. It also chips nicely unlike UHMW and Nylon. Some plastics, like UHMW, have the unfortunate tendency to render the dials on a mill or lathe meaningless as the plastic deflects away from the tool. POM does not do this as much. Of course these other plastics have their strengths as well, but if any plastic will do, and you’re machining, POM is a very good choice.

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Swarm Of Tiny Pirate Transmitters Gets The Message Out In Syria

March 3, 2016 by 76 Comments

They say that the first casualty of war is the truth, and that’s probably only more the case in a civil war. When one side in a conflict controls the message, the other side is at a huge disadvantage. Technology can level the playing field, and in the case of the Syrian Civil War, a swarm of tiny Raspberry Pi transmitters is helping one side get their message out.

We won’t pretend to understand the complexities of this war, but it’s clear that the Syrian government controls broadcast media and access to the internet, and is using them for propaganda while denying the opposition access to the same. A decentralized medium can get the message out under these conditions, and that’s exactly what Pocket FM does. Built around a Raspberry Pi and a frequency-agile FM transmitter, a Pocket FM can take multiple audio feeds and transmit them out to a 5km radius. Small enough to be packed up and deployed quickly and able to be powered by batteries or solar panels, the pirate transmitters can be here one minute and gone the next, yielding a robust network resistant to takedown attempts.

The network built around Pocket FM in Syria is small but growing, and it appears to be making a difference in the conflict. We find the concept of a decentralized network intriguing and potentially empowering, at least in situations where the letter of the law regarding broadcasting is not a prime consideration. That’s where projects like Airchat seek to build an unsanctioned network. The same goes for Tweeting on the Amateur Radio Band in a project aptly named HamRadioTweets.

We wonder how a fleet of these Pi-based transmitters could aid in recovery from natural disasters?

[via r/amateurradio and TomHiggins]

Broken Promises Of The Wankel Engine

March 3, 2016 by 168 Comments

Through the history of internal combustion engines, there has been plenty of evolution, but few revolutions. Talk of radically different designs always leads to a single name – Wankel. The Wankel rotary engine, most notably used in automobiles by Mazda, has been around since the late 1950’s. The Wankel rotary is an example of a design which makes sense on paper. However, practical problems cause it to underperform in the real world.

Invention and History

felixwankelFelix Wankel’s engine was conceived during a dream. In it, 17-year-old Felix was driving his car to a concert. When he arrived, he bragged to his friends that his car used a new type of engine – half turbine, half reciprocating. “It is my invention!” he told his friends. Upon waking up, Wankel became dedicated to building his engine. Though he never received a formal degree (or a driver’s license), Wankel was a gifted engineer.

Young Wankel’s checkered history includes membership in several anti-semitic groups in the 1920’s. He was also involved with the founding of the Nazi party. His conflicting views on the direction of the party lead to his arrest in 1933. Eventually released through action of Hitler himself, Wankel joined the SS in 1940. The end of the war saw Wankel spending several months in a French prison for his wartime involvement.

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Overclocking The Raspberry Pi 3 For Tasty Speed Increases

March 3, 2016 by 47 Comments

Some people are never happy. [Jackenhack] got hold of a couple of shiny new Raspberry Pi 3s, and the first thing he did is to start overclocking them. Fortunately, he knows what he is doing, so none of the magic smoke escaped, but it seems not all Pis are happy with the process.

For one of the three seemingly identical Pi 3, adding heat sinks let him push the CPU from the native 1.2GHz up to 1.45GHz. That did involve a bit of overvolting (increasing the voltage to the CPU), but that can be easily done in software. He also experimented with adding heat sinks to the memory, then bumping up the speed of the memory to increase throughput. Again, he was able to make some impressive gains, bumping the speed up from the native 400 Mhz to 500 Mhz. Both of those are stable overclocks: he was able to run the system at 100% CPU load for an extended time, and has incorporated the overclocked Pi into his system that contributes to the NTP pool project.

However, when he tried the same overclock with the second of the Pi 3 victims test subjects, it failed due to the CPU overheating. So, it seems that there is a lot of variation in the individual bits of silicon on the Pi 3. Perhaps some liquid nitrogen would help? It did for an Arduino…

Incredible Marble Music Machine

March 3, 2016 by 44 Comments

We tried to figure out how to describe the band [Wintergatan]. It took a lot of googling, and we decided to let their really incredible music machine do it for them. The best part? Unlike some projects like this that come our way, [Wintergatan] documented the whole build process in an eight part video series.

The core of the machine is a large drum with two tracks of alternating grey and black Lego Technic beams and pins. The musician sequences out the music using these. The pins activate levers which in turn drop ball bearings on the various sound producing devices in the machine. The melody is produced by a vibraphone. At first we thought the drum kit was electronic, but it turns out the wires going to it were to amplify the sound they made when hit. At the end of their travel the bearings are brought up to the hopper again by a bucket conveyor.

The final part count for the machine sits at 3,000 not including the 2,000 ball bearings rolling around inside of it. If you’ve ever tried to make a marble machine, then you’ll be just as impressed as we were that the machine only appeared to lose a few marbles in the course of a three minute song. Aside from the smoothness of the machine, which is impressive, we also enjoyed the pure, well, hackiness of it. We can spy regular wood screws, rubber bands, plywood, bits of wire, and all sorts of on-the-spot solutions. Just to add bonus cool, the whole project appears to have been built with  just a bandsaw, a drill press, and a few hand power tools.

The machine is great, but we also really appreciate the hacker spirit behind it. When a commenter on a YouTube video told him he was a genius, he replied, “Thank you for that! But I do think, though, that it is mostly about being able to put in the time! I mean the talent of being stubborn and able to see things through are more important than the abilities you have to start with. If you work hard on anything, you will learn what you need and success! Its my idea anyway! So happy people like the machine!”. Which we think is just as cool as the machine itself. Video of the machine in action and part one of the build series after the break!

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A Spicy Regenerative Reciever

March 2, 2016 by 16 Comments

We recently posted a three-part series about using LTSpice to simulate electronic circuits (one, two, three). You might have found yourself wondering: Can you really simulate practical designs with the program? This quick analysis of [QRP Gaijin’s] minimalist regenerative receiver says “yes”.

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