The BatBox: Portable Power, Polished And Professional. Plus Smoke!

August 13, 2013 by 26 Comments

batBox

About the size of a shoebox and stuffed with a compact battery/inverter combo, the BatBox packs a mean wallop at 480Wh. What else was [Bill Porter] supposed to do with his free time? He’s already mailed out electronic wedding invitations and built custom LED centerpieces for the reception. He and his wife [Mara] then made an appearance in a Sunday roundup tying the knot by soldering a circuit together. Surely the LED Tetris Tie would have been in the ceremony had it existed. This time, though, [Bill’s] scrounged up some leftover electronics to put a realistic spin on a Minecraft favorite: the BatBox.

A pair of 18V high energy density batteries connect up to a 12V regulator, stepping them down to drive a 110VAC inverter. The BatBox also supplies 5V USB and 12VDC output for portable devices. Unfortunately, [Bill]’s first inverter turned out to be a low-quality, voltage-spiking traitor; it managed to let the smoke out of his fish tank’s LED bar by roasting the power supply. Undeterred, [Bill] pressed on with a new, higher-quality inverter that sits on an acrylic shelf above the batteries. OpenBeam aluminum extrusion seals up the remainder of the enclosure, completing the BatBox with a frame that looks both appealing and durable.

Air-powered Gripper Design Makes Them Easy To Produce

June 30, 2013 by 7 Comments

air-powered-gripper

This invertebrate gripper uses air pressure to grab onto objects. The secret is all in the design. But you don’t have to reinvent the wheel. If you’ve got a 3D printer you can follow this guide to make your own.

The gripper is made of silicone. The trick is in designing an inner structure that deforms in one direction when pressurized. To make one or one hundred, simply download the design files and 3D print a mold. The process from there is much like the silicone band prototyping process we looked at back in March. The two-part silicone is mixed and poured in the mold. You also need to pour some on a flat surface. We were under the impression that uncured silicone would not stick to cured silicone but we were wrong. The two parts are glued together with a fresh batch of the mix. After everything has set up you can pierce the bladder with a hose in order to inject air.

Below you can see the star-shaped version being tested. There’s also a Harvard research video which shows a similar design lifting an egg.

Continue reading “Air-powered Gripper Design Makes Them Easy To Produce” →

Hackers In Africa Are Building Their Own Aircraft

June 27, 2013 by 78 Comments

hacked-heli

While you’re trying to come up with an idea for your next project this guy’s been building his own helicopter from whatever parts he can find. He’s just one of the aeronautical hackers featured in a story in the Daily Mail. The article’s narrative leaves us with many questions, but there’s enough info to make it worth a look.

In addition to the heli seen above there are also a couple of airplane builds to gawk at. Africa has already produced a couple of very ingenious hacks like [William Kamkwamba’s] projects which improved his village infrastructure. He gained enough notice from his work to land a scholarship to continue his education and that opportunity has also been afforded the creators of these aircraft.

At first we figured this helicopter project was possible because of lack of air traffic regulation in this part of the world. That’s not the case as [Onesmus Mwangi] — who makes his living as a farmhand — has been forbidden to fly the craft by local police. There may be another opportunity for him to fly later in life. He’s received funding to study aircraft maintenance abroad.+

Unfortunately we couldn’t find any video of this thing in action. If that’s unacceptable to you try getting your fix from this human-sized octocopter.

[Thanks Brandon]

Adding WiFi To A Kid’s Tablet

June 17, 2013 by 6 Comments

tab

[Mick] has been playing around with the VTech Innotab – a $70 tablet computer aimed at kids – for a while now. He’s successfully turned this tablet soon to be found at yard sales the world over into a Linux tablet and can play everything from those magical LucasArts SCUMM adventure games to Angry Birds. What his tablet is missing, though, is any sort of Internet connection. He recently fixed this by soldering a USB WiFi adapter directly to the CPU of his InnoTab.

In all fairness, there’s not a terrible amount of software hackery going on here. VTech’s InnoTab 2s uses the same chipset as the cheaper InnoTab 2 but has an additional board soldered directly to the mainboard. This additional board provides a WiFi connection with an RT5370 chipset; soldering a WiFi dongle onto the InnoTab 2’s CPU D+ and D- USB lines effectively turns it into the WiFi enabled InnoTab 2s.

It’s an impressive piece of work for a low-power tablet that one can safely assume is both bullet and childproof. [Mick] was also able to mount a USB thumb drive on his upgraded kid’s tablet, so if you’re looking for a cheap tablet that doesn’t need much horsepower, you might want to check out your local Toys ‘R Us.

Robot Air Hockey Championship As A Final Project

May 18, 2013 by 17 Comments

clemson-air-hockey-robots

My final project is build a robot that plays air hockey? Where do I sign up? Apparently you get yourself a seat in ECE496 at Clemson University. They have been using the concept as a final project for at least a couple of years. [Abe Froman] was on the winning design team this year and he’s showing off his robot and some winning games it played.

His robot is in the foreground. It uses a right-angle PVC joint to hold the paddle. The fitting is attached to a rack and pinion that drives it forward and back. The entire assembly is mounted on a rotating rig. Take a look at some of its opponents that use more of a plotter-type arm. Those offerings have too much play in the joints which at times causes the thing to miss.

Chances are good that once you get a job you won’t be asked to do things for the company unless they are money makers. Sure, there are a few notable exceptions,  but since you’re playing to go to school we really appreciate the professors making the learning as enjoyable as possible before you have to get serious (and maybe even wear a tie!).

Continue reading “Robot Air Hockey Championship As A Final Project” →

A Tiny Custom Table Saw

March 25, 2013 by 33 Comments

saw

If you’re working with small parts, even the smallest table saw available at Home Depot or Lowes is generally overkill. For cutting up small pieces of wood, metal, and copper-clad board, a micro table saw is a great investment. They’re actually pretty inexpensive, but why just buy one when you can make one that is better than any model on the market?

The bed is constructed out of 1/4″ aluminum plate with a 1/15 horsepower motor bolted to the underside. The fence clamps on to the table with a pair of delrin brackets, while the angle guide is made of delrin and a brass bar that fits into a slot in the table.

The actual blades came from a Proxxon micro table saw (a very good brand from our experience), but comparing this homemade saw to the commercial one provides a few surprises: The Proxxon has a more powerful motor, but the homebrew version has four times the cutting capacity. You can check out this saw cutting a 1/4″ aluminum bar in the video after the break.

Thanks [Hubert] for sending this one in.

Continue reading “A Tiny Custom Table Saw” →

Repairing Broken Injection Molded Parts With A 3D Printer

March 15, 2013 by 28 Comments

injection-molded-part-repair

The value of a 3D printer is obvious for people who hack hardware as a hobby. But this repair project should drive home their usefulness for the commoner. [James Bruton] used a 3D printer to recreate a hopelessly broken injection molded plastic part. This is a suction cup mounting bracket for a Tom Tom GPS module. The sphere which makes it adjustable had broken off of the column holding it. For 100% of non-hacking consumers that’s the end of this item. We can’t see a fix that would restore the strength of the original part.

The replacement starts by measuring the broken part with precision calipers. [James] then grabbed a copy of 123D, which is free software. He starts by modeling the sphere, then builds up the support column and the base with a cut-out. It’s obvious he’s already very familiar with the software, but even the uninitiated should be able to get this done pretty quickly. After slicing the design for the 3D printer he finds the part will be ready in about 11 minutes. The first prototype is a bit too small (the ball requires close tolerances to work well). He spins up a second version which is a bit large and uneven. A few minutes of filing leaves him with a smooth sphere which replaces the original part beautifully!

You can see the entire design, print, and assembly process in the clip after the break.

Continue reading “Repairing Broken Injection Molded Parts With A 3D Printer” →