A Cheap Honeycomb Table Replacement For Your Laser

February 22, 2014 by 36 Comments

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CO2 lasers make use of a honeycomb table which allows you to support parts you are cutting — without cutting into the bed too much. Unfortunately they are a consumable part, so they will eventually wear out, and they aren’t that cheap. [Claptrap] came up with an excellent alternative.

A few months ago, his radiator blew in his station wagon, and it had to be replaced. He was about to throw it out when he realized the similarity of the radiators cooling fins, to that of his honeycomb table… He cut it down to size, pressure washed it (though he notes you should probably wash it first before cutting) and put it in place. It works great!

The only caveat we have is that you should probably flush the radiator with a water pump first — you don’t want to be heating up any residual radiator fluid inside the radiator channels!

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FLUX 1440: A Highly Impractical But Awesome Clock

February 22, 2014 by 52 Comments

One our tipsters just sent us this great project — it’s a unique style of clock that we haven’t seen before. It was completed as part of what we think was a post-graduate program by [Felix Vorreiter]. This is FLUX 1440 (translated).

It uses 1200 meters of marked rope that is fed into the clock and strung between various pulleys and gears. Every second, the rope is moved 1.3cm. Every 57 seconds, the time is readable across the strands of rope — but only for 3 seconds. After that everything goes “back into the river”, a metaphor for chaos.

The explanation behind it is in German, but we’ve tried to piece together a general statement about the meaning behind it. Of course, we’d love if one of our German readers could provide a better translation!

FLUX 1440 displays time as a spatial dimension and counts the length of a day using a long segmented rope. The length of each minute is felt physically, as the viewer must wait as the shapes change until the current time reveals itself from the chaos of the markings.

Stick around for an extremely well produced video demonstrating it — it’s also in German, but we think you’ll be able to piece together the meaning.

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Listening To A Smart Scale

February 22, 2014 by 2 Comments

[Saulius] couldn’t find a cost-effective wireless scale that did what he wanted, so he reverse engineered the communication protocol for an off the shelf model to get weight data himself.

[Saulius] bought a cheap Maxim 29-66SH scale that uses infra-red to communicate to a detachable digital readout. Using the USB IR toy, [Saulius] intercepted the messages that were broadcast. After a little reverse engineering and with the help of some Python scripts, he soon discovered the protocol his scale was using to encode weight messages.

[Saulius] went on to write a little web app using JavaScript, SocketIO and Tornado, a light weight Python web server. By connecting to the tiny web server that’s interfaced with a Python script listening for the scales messages received from the USB IR toy, [Saulius] was able to see his weight displayed on his smart phone through a web browser.

Since all the communication is through IR, there is no need to do any invasion of the scale as the receiver can be placed anywhere in line of sight from the transmitter on the scale itself.

Check out the demo video for the whole thing in action. If patching into the scale isn’t hard enough, you should just build one from scratch.

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Smart Reflow Oven Is Over-Engineered

February 22, 2014 by 28 Comments

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[Linas] reverse engineered an AMOLED HTC 800×480 screen and interfaced it with an STM32 micro-controller, along with some other components, to make a gorgeously over engineered reflow oven.

Under the hood there is a PSoC5LP PID controller to control the 800W IR heating coil and two K-type thermocouples for sensing.

The real beauty is in the relatively small STM32 chip powering the HTC AMOLED screen. The AMOLED screen is high contrast and has a wide viewing angle, giving it a clear crisp view from all front facing viewpoints. Though pushing the limits of what the STM32F429i can do, [Linas] managed to make a very nice “home-grown” user interface, complete with user configurable settings and current temperature graphs.

The user interface looks very responsive and using some clever programming, [Linas] was able to make use of the potential of the screen to provide beautiful plots and interface widgets.

[Linas] goes into quite a bit of detail about the programming involved with rendering to the screen, so be sure to check out the video after the jump.

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Researchers Create Synthetic Muscle 100 Times Stronger Than The Real Thing

February 21, 2014 by 110 Comments

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A team of researchers at the University of Texas at Dallas have come up with an ingenious way to make a low-cost, high strength, artificial muscle. Their secret? Fishing line. The study was just published today in the journal Science, and the best part is they describe how to recreate it at home.

To create it, the researchers take regular fishing line (polyethylene or nylon string) and twist it under tension until it curls up into a tightly formed spring. It can then be temperature treated to lock in this position.

When heated again, the plastic tries to untwist — the peculiar thing is, this causes the entire coil to compress — think of it as Chinese finger-trap. Polyethylene and nylon molecules also contract lengthwise when heated. It can contract up to about 49%, with as much pulling power as 100 times its equivalent human muscle in weight. This equates to about 5.3 kilowatts of mechanical work per kilogram of muscle weight — similar to the output of a jet engine.

Stick around to see the video of how to make it — we’re excited to see what you guys think up for project applications!

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Dual Color Extruder With A Single Stepper

February 21, 2014 by 18 Comments

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Once you have a 3D printer able to build a few objects in a single color, the next logical upgrade is a dual extruder. A dual extruder allows for multiple color prints, and by adding a dissolvable filament, the ability to print object that would otherwise be impossible. Fitting a dual extruder on an existing 3D printer presents a problem: simply by using a second stepper motor, you reduce the print area of your printer significantly. That’s the problem Dglass 3D aims to solve with their extruder. It’s a dual filament extruder that uses only one stepper motor and takes up less space than some other single filament extruders.

This isn’t the first time the guys at Dglass 3D have tried Kickstarting a dual filament extruder; last year we saw a very similar mechanism that used a single stepper motor to feed two filaments. This older model lacked retraction, though, meaning two colored prints would range somewhere between messy, inaccurate, to impossible.

The new extruder uses a servo to ‘latch’ the filament and drive it into the hot end. This means retraction of the filament is possible and from the sample prints with this extruder, the results look pretty good.

Below You’ll see a few video demos of the dual color/retraction extruder printing an object in black and white filaments at the same time. It’s very cool, and with the addition of a dissolvable filament means very complex objects can be printed very easily.

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Meltinator 9000 Fuses Glass By Degrees

February 21, 2014 by 11 Comments

kiln[Richard]’s wife scored an Evenheat glass-fusing kiln, but the 20-year-old temperature controller was broken. He could have simply ordered a replacement controller, but that kind of problem solving doesn’t get you on Hack a Day. His wife wanted more control over the kiln and he convinced her that building their own was the way to go. Thus, the Meltinator 9000 was born.

[Richard]’s design uses an Arduino Uno and an Adafruit display shield, protoshield, and thermocouple reader board. He built a simple relay driver with a resistor, BJT, and a diode and connected it to pin 13 and its built-in indicator. To [Richard]’s delight, all of this fit in the original enclosure.

[Richard]’s software provides 25 fusing schedules with ten steps apiece. Each step has a target temperature,  rate of temperature change, and a hold time which can be increased on the fly. He ran a test program that heated the kiln to 1500°F at a rate of 2550°F/hour. He then cooled it to 500°F at a rate of 1000°F/hour, which took longer than he thought. The good news is that the kiln is well-insulated!  [Richard] has the software available on his GitHub.

Don’t have a glass kiln? Prefer to control beer-related temperatures? You could always hack your stove in the name of homebrewing.