Arc Reactor Replica Could Have Been Crafted In A Cave

June 11, 2013 by No comments

arc-reactor-replica

Following in the footsteps of [Tony Stark] this Arc Reactor replica was hand crafted using almost no power tools. From what we can tell in his build gallery, a cordless drill was his only departure from using pure elbow grease.

[DJ Maller] started his build by cutting out a disc of acrylic for the base plate. While we might have reached for a hole saw, he grabbed a framing square and laid out a center point and square cuts on the stock. Kudos for his use of an awl (we often take the Luddite approach of hammer and nail) to make an impression for his compass point to rest in. After using a coping saw to rough out the shape he sands the round up to the line with the drill and a sanding wheel.

After drilling holes and inserting LEDs he begins to build up the replica piece by piece. What looks like a recessed handle for a sliding closet doors makes up the center. The spring-like copper coils was produced by wrapping wire around a pen then stretching to the desired shape. He added a bicycle spoke wrench wrapped with copper for some additional visual appeal before finishing the decoration off with some storm door clips.

[via Reddit]

An Interview With Shapeways

June 11, 2013 by 11 Comments

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It seems [Andrew] is an up and coming historian for the world of 3D printing. We’ve seen him interview the creator of Slic3r, but this time around he’s headed over to Eindhoven, Netherlands to interview the community manager for Shapeways, [Bart Veldhuizen].

Unlike the RepRaps, Ultimkers, and Makerbots, Shapeways is an entirely different ecosystem of 3D printing. Instead of building a machine that requires many hours of tinkering, you can just upload a model and have a physical representation delivered to your door in a week. You can also upload objects for others to buy. Despite these competing philosophies, [Bart] doesn’t see Shapeways as encroaching on the homebrew 3D printers out there; they serve different markets, and competition is always good.

Unfortunately, [Andrew] wasn’t allowed to film on the Shapeways factory floor. Proprietary stuff and whatnot, as well as a few certain ‘key words’ that will speed your customer support request up to the top of the queue.

As for how Shapeways actually produces hundreds of objects a day, [Andrew] learned that individual orders are made in batches, with several customer’s parts made in a single run. While most of the parts made by Shapeways are manufactured in-house, they do outsource silver casting after making the preliminary positive mold.

As for the future, a lot of customers are asking about mixed media, with plastic/nylon combined with metal being at the top of the list. It’s difficult to say what the future of 3D printing will be, but [Bart] makes an allusion to cell phones from 10 years ago. In 2003, nobody had smartphones, and now we have an always-on wireless Internet connection in our pockets. Given the same rate of technological progress, we can’t wait to see what 3D printing will be like in 10 years, either.

Giving Toys An Electronic Voice

June 11, 2013 by 20 Comments

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Whether it’s a Furby or Buzz Lightyear’s button that plays, ‘To infinity and beyond’, most digital audio applications inside toys are actually simple affairs. There’s no Arduino and wave shield, and there’s certainly no Raspi streaming audio from the Internet. No, the audio inside most toys are one or two chip devices capable of storing about a minute or so of audio. [makapuf] built an electronic board game for his kids, and in the process decided to add some digital audio. The result is very similar to what you would find in an actual engineered product, and is simple enough to be replicated by just about anyone.

[makapuf]’s game is based on Game of the Goose, only brought into the modern world with electronic talking dice. An ATtiny2313 was chosen for the microcontroller and an AT45D 4 Megabit Flash module provided the storage for 8 bit/8khz audio.

The electronic portion of the game has a few functions. The first is calling out numbers, which is done by playing recordings of [makapuf] reading, ‘one’, ‘two’, ‘three’, … ‘twelve’, ‘thir-‘, ‘teen’ and so on. This data is pumped out over a pin on the ATtiny through a small amplifier and into a speaker. After that, the code is a simple matter of keeping track of where the players are on the board, keeping score, and generating randomish numbers.

It’s an exceptional exercise in engineering, making a quite complicated game with a bare minimum of parts. [makapuf] estimated he spent under $4 in parts, so if you’re looking to add digital audio to a project on the cheap, we can’t imagine doing better.

You can see a video of [makapuf]’s project after the break.

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60,000 RPM Vacuum Powered Rotary Tool Was 3D Printed

June 11, 2013 by 61 Comments

vacuum-powered-rotary-tool

The whining of the turbines in the 3D printed pneumatic rotary tool might make your teeth hurt. When [Axodus] tipped us off about it he mentioned it sounded like a 747 taking off. But we hear a dentist’s drill when watching the demo video.

[Richard Macfarlane] published his design if you want to try building one for yourself. But you will need to do some machining in addition to printing the enclosure and the pair of turbines. The shaft of the tool needs to fit the bearings precisely. It accepts a center blue spacer with a red turbine on either side. This assembly is encapsulated in the two-part threaded blue body which has a flange to friction fit with the shop vacuum hose. The business end of the machined shaft was designed and threaded to accept the collet from a Dremel or similar rotary tool.

We wonder how much work it would be to re-engineer this to act as a PCB drill press?

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Automated Programming And Testing Jig Built With Raspberry Pi

June 10, 2013 by 5 Comments

[Doug Jackson] makes word clocks, and he must be doing quite a bit of business. We say that because he put together a programming and test bed for the clock circuit boards.

This is a great example to follow if you’re doing any kind of volume assembly. The jig lets the populated PCB snap into place, making all the necessary electrical connections. This was made possible by a package of goods he picked up on eBay which included rubber spacers to separate the board from the acrylic mounting plate, pogo pins to make the electrical connections, and a spring-loaded board clamp seen to the left in this image.

The switch in the lower right connects power to the board and pulls a Raspberry Pi GPIO pin high. The Python script running on the RPi polls that pin, executing a bash script which programs the ATmega169 microcontroller using the GPIO version of AVRdude. We looked through his Python script and didn’t see code for testing the boards. But the image above shows a “Passed” message on the screen that isn’t in his script. We would wager he has another version that takes the hardware through a self test routine.

We first saw one of [Doug’s] word clocks back in 2009 and then again a few months later. The look of the clock is fantastic and it’s nice to see the project is still going strong.

Gesture Control Uses WiFi Doppler Shift

June 10, 2013 by 29 Comments

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We’ve said it before: in the future simple interfaces will use nothing but your body. At least at first glance that’s the case with this WiFi-based gesture control system. If you have Internet at home you probably have a WiFi access point. That’s the first portion of the equation. The remainder is a way of measuring how the radio waves bounce off of your body. So far this is being done with Software-Define Radio (SDR) but researchers at University of Washington think it may be possible to build the technique into future WiFi devices.

The demo video shows this man waving his arm to adjust the volume of his home entertainment system. Intuition tells us that this would be impossible if your arm wasn’t the only thing in motion at the time. But that issue is quickly addressed. Multiple antennas can track multiple people at the same time. There is also consideration for false-positives. The system requires a moderately complex wake-up gesture sequence to prevent you from, say, accidentally turning on the stereo when you roll over in bed.

If you’re having trouble wraping your mind around this, consider this ultrasonic music player. The WiFi version does the same thing, but processing changes in the returning radio waves is much more complex.

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Incredible Bow Lathe Work In Morocco

June 10, 2013 by 13 Comments

Bow lathes are a fairly old an simple contraption. A bow is used to rotate a block of wood back and forth while tools can be used to shape it, just like a modern lathe. Despite the fact that the wood is oscillating instead of spinning in one direction, the results are very smooth.

Watch as this street vendor shows his skills with the bow lathe. I find it quite impressive how well he uses his foot. You can tell he’s been doing this for a very long time. I was also pleasantly surprised when that ring popped free, I wasn’t expecting it.

[thanks Rudolph]