Adding Recycling Codes To 3D Prints

March 18, 2015 by 21 Comments

Every little plastic bauble you interact with has some sort of recycling code on it somewhere. Now that we’re producing plastic 3D printed parts at home, it would be a good idea to agree on how to recycle all those parts, and [Joshua Pearce]’s lab at Michigan Tech has the answer; since we’re printing these objects, we can just print the recycling code right in the object.

The US system of plastic recycling codes is particularly ill-suited for identifying what kind of plastic the object in question is made of; there are only seven codes, while China’s system of plastic identification uses 140 identification codes. This system for labeling 3D printed parts borrows heavily from the Chinese system, assigning ABS as ‘9’, PLA as ’92’, and HIPS as ‘108’.

With agreed upon recycling codes, the only thing left to do is to label every print with the correct recycling code. That’s an easy task with a few OpenSCAD scripts – the paper shows off a wrench made out of HIPS labeled with the correct code, and an ABS drill bit handle sporting a number nine. 3D printing opens up a few interesting manufacturing techniques, and the research team shows this off with a PLA vase with a recycle code lithophane embedded in the first few layers.

Crazy Whirlwind Pre-Hackaday Prize Launch Tour

March 18, 2015 by 3 Comments

The Hackaday Prize was about to launch but the date wasn’t public yet. I decided to do a pre-launch tour to visit a few places and to drop in on some of the Hackaday Prize Judges. It started in Chicagoland, looped through San Francisco for a hardware meetup and Hardware Con, then finished with visits to [Ben Krasnow’s] workshop, [Elecia White’s] studio, and the Evil Mad Scientist Laboratories.

The Prize is now running and it’s time for you to enter. Look at some of the awesome hacking going on at the places I visited and then submit your own idea to get your entry started. Join me after the break for all the details of the adventure.

Continue reading “Crazy Whirlwind Pre-Hackaday Prize Launch Tour” →

How To Directly Program An Inexpensive ESP8266 WiFi Module

March 18, 2015 by 121 Comments

The ESP8266 is the answer to “I want something with Wifi.” Surprisingly, there are a number of engineers and hobbyists who have not heard of this chip or have heard of it but don’t really understand what it is. It’s basically the answer to everything IoT to so many engineering problems that have plagued the hobbyist and commercial world alike.

The chip is a processor with integrated RAM, some ROM, and a WiFi radio, and the only external components you will need are 4 capacitors, a crystal and an external flash! It’s CHEAP, like $4/ea cheap! Or $5 if you want it on a nice, convenient carrier board that includes all these components. The power consumption is reasonable (~200mA)1, the range is insane ~300m2 without directional equipment, and a PCB trace antenna and ~4km if you want to be ridiculous.

One place thing that more people need to know about is how to program directly for this chip. Too many times projects use it as a crutch via the AT commands. Read on and find out how to hello world with just this chip.

Continue reading “How To Directly Program An Inexpensive ESP8266 WiFi Module” →

An Experiment In Shift Registers And Multiplexed LEDs

March 18, 2015 by 15 Comments

[Kratz] is working on a WiFi controlled scoreboard, but before building the full-scale version, he thought it would be wise to test out the multiplexing technique for the display. The experiment worked, but unless this scoreboard is for a foosball table, he still has a lot of work ahead of him.

The design of this prototype display is pretty simple, with just two ‘595 shift registers feeding bits to the display. Sixteen NPN transistors are being used to sink and source current to the display. It’s a relatively simple circuit, allowing [Kratz] to fit nine seven-segment displays on a small board with only six wires – ground, two V+ for the logic and LEDs, clock, data, and latch – going to the microcontroller.

There were a few snags in the design; the data is clocked in on a rising edge, but an extra falling edge was required before latching. [Kratz] can’t figure out the reason for this, and it might just be a timing issue.

Lathe Tach

Excuse Me, Sir. Do You Know How Fast Your Lathe Was Traveling Back There?

March 18, 2015 by 26 Comments

When machining metal, it is important to know how fast the cutting tool is traveling in relation to the surface of the part being machined. This amount is called the ‘Surface Speed’. There are Surface Speed standards for cutting different types of materials and it is good practice to stick with those standards in order to end up with a good surface finish as well as maximizing tool life. On a lathe, for example, having a known target Surface Speed in mind as well as a part finish diameter, it is possible to calculate the necessary spindle speed.

Hobbyist [Paul] wanted a method of measuring his lathe’s spindle speed. Since spindle speed is measured in RPM, it made complete sense to install a tachometer. After browsing eBay for a bit he found one for about $20. His purchase came with the numeric LED display, a mounting bezel and the all important hall effect sensor. The Hall effect sensor measures changes in a magnetic field and in turn varies its output voltage. [Paul] fabbed up an aluminum bracket that supports the sensor just off of the rear of the lathe spindle. A magnet was then glued to the outside diameter of the spindle below the sensor. The once per revolution signal is generated every time the magnet passes the sensor while the lathe is running. The display was mounted to the lathe near eye height by means of another aluminum bracket and case.

After a little work, [Paul] can now keep a close eye on his spindle speed with a quick glance over at his new tachometer display while he’s turning those perfect parts! If this project tickles your fancy, you may want to check out this fantastic DIY tachometer or this one that uses a soundcard.

Toggle Magnet

Switchable Magnet With A Simple Circuit

March 17, 2015 by 26 Comments

Magnets are awesome. Electromagnets are even cooler. But what if you could make a semi-permanent switchable magnet that acts like an electromagnet, but doesn’t use any energy to hold metal? You’re going to want to take a look at this Low-power Magnetic Hold and Release Mechanism.

It’s actually a very simple concept. It is basically an electromagnet attached to a permanent magnet — it’ll hold any metal object exactly as you’d expect — but if you run current through the inductor attached to it, the magnetic field created by the electricity will temporarily cancel out the field of the magnet — thus freeing your object being held. Since gravity is pretty fast acting, this impulse of current doesn’t need to be very long, only fractions of a second.

Now the real question is how big could you go? We covered another project a while ago called Open Grab which discusses the possibility of using technology like this in Quadcopters.

For a solution that uses no power at all take a look at switchable magnet clamps used for welding — they’re pretty cool — but patent protected of course.

Putting New Into The Old – A Phonograph Upgrade.

March 17, 2015 by 28 Comments

[smellsofbikes] recently came into possession of a 1970’s “stereo radio phonograph” cabinet consisting of a vinyl record player, AM and FM radio, and eight track tape player. The radio worked, the turntable didn’t sound too nice, and the tape player didn’t work at all. A new needle fixed the turntable, but the eight-track was in bad shape. So he replaced the tape player with a BeagleBoneBlack which plays streaming internet radio.

Hopefully, this fix is temporary, since he has carefully disconnected the tape player connections in the hope of fixing it soon. The swap out involved a fair bit of engineering, so he’s split his build log into several bite sized chunks. The first step was to set up the BBB, upgrade it and add in all the network and audio related stuff. Audio on the BBB is available only via the HDMI port, but [smellsofbikes] had a USB soundcard handy, so the next step was setting that up. He installed mpg321 – the command line mp3 player and set it up to play music streaming from somafm. Next up was getting some scripts and programs to run automatically during system bootup. The final part of the setup was adding a WiFi router as a repeater connected to the BBB via an ethernet cable. He could have used a tiny WiFi USB dongle, but he already had the router lying around, and he wanted to dedicate USB to audio functions alone, and use the Ethernet port for Internet.

He then worked on identifying the wires that go from the tape player to the amplifier, spliced them, and hooked them up to the audio sound card on the BBB. With this done, the upgrade was more or less complete – the system played streaming music and stations could be switched remotely (via SSH to BBB). [smellsofbikes] reckoned it would be nice to use the existing controls in the phonograph cabinet to control the internet streaming music, instead of controlling it via a remote computer. The cabinet had 4 indicator lamps that indicated which track was being played and a button to switch between tracks. He removed the old indicator panel and put in a fresh PCB, designed in KiCad and cut on his LPKF circuit board plotter. An aluminum knob machined out of hex bar-stock works as the new track change button. At this point, he called it a wrap. The BBB and Asus router go inside the cabinet, and the old (non-functional) tape player is put in place. Quite an interesting build, and we look forward to when he actually gets the tape player working. [Alan Martin], aka “The Most Interesting Engineer In The World” has told him that “it is a moral imperative that you repair the eight-track and get it working”. [Alan] has promised to send [smellsofbikes] a suitcase full of brand new, still in their plastic wrappers, eight-track tapes when he gets it working.