Studying The Finer Points Of 3D Printed Gears

June 12, 2024 by 34 Comments

[How to Mechatronics] on YouTube endeavored to create a comprehensive guide comparing the various factors that affect the performance of 3D printed gears. Given the numerous variables involved, this is a challenging task, but it aims to shed light on the differences. The guide focuses on three types of gears: the spur gear with straight teeth parallel to the gear axis, the helical gear with teeth at an angle, and the herringbone gear, which combines two helical gear designs. Furthermore, the guide delves into how printing factors such as infill density impact strength, and it tests various materials, including PLA, carbon fiber PLA, ABS, PETG, ASA, and nylon, to determine the best options.

The spur gear is highly efficient due to the minimal contact path when the gears are engaged. However, the sudden contact mechanism, as the teeth engage, creates a high impulse load, which can negatively affect durability and increase noise. On the other hand, helical gears have a more gradual engagement, resulting in reduced noise and smoother operation. This leads to an increased load-carrying capacity, thus improving durability and lifespan.

It’s worth noting that multiple teeth are involved in power transmission, with the gradual engagement and disengagement of the tooth being spread out over more teeth than the spur design. The downside is that there is a significant sideways force due to the inclined angle of the teeth, which must be considered in the enclosing structure and may require an additional bearing surface to handle it. Herringbone gears solve this problem by using two helical gears thrusting in opposite directions, cancelling out the force.

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Displays We Love Hacking: DSI

June 12, 2024 by 10 Comments

We would not be surprised if DSI screens made up the majority of screens on our planet at this moment in time. If you own a smartphone, there’s a 99.9% chance its screen is DSI. Tablets are likely to use DSI too, unless it’s eDP instead, and a smartwatch of yours definitely will. In a way, DSI displays are inescapable.

This is for a good reason. The DSI interface is a mainstay in SoCs and mobile CPUs worth their salt, it allows for higher speeds and thus higher resolutions than SPI ever could achieve, comparably few pins, an ability to send commands to the display’s controller unlike LVDS or eDP, and staying low power while doing all of it.

There’s money and power in hacking on DSI – an ability to equip your devices with screens that can’t be reused otherwise, building cooler and cooler stuff, tapping into sources of cheap phone displays. What’s more, it’s a comparably underexplored field, too. Let’s waste no time, then!

Decently Similar Internals

DSI is an interface defined by the MIPI Alliance, a group whose standards are not entirely open. Still, nothing is truly new under the sun, and DSI shares a lot of concepts with interfaces we’re used to. For a start, if you remember DisplayPort internals, there are similarities. When it comes to data lanes, DSI can have one, two or four lanes of a high-speed data stream; smaller displays can subsist with a single-lane, while very high resolution displays will want all four. This is where the similarities end. There’s no AUX to talk to the display controller, though – instead, the data lanes switch between two modes.

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Baldur’s Gate III Comes To The TRS-80 Model 100

June 12, 2024 by 8 Comments

To say that Tandy’s TRS-80 Model 100 was an influential piece of computer hardware would be something of an understatement. While there’s some debate over which computer can historically be called the “first laptop”, the Model 100 was early enough that it helped influence our modern idea of portable computing. It was also one of the most successful of these early portables, due in part to how easy it was to write your own software for it using the built-in BASIC interpreter.

But as handy and capable as that integrated development environment might have been, it never produced anything as impressive as this Baldur’s Gate III “demake” created by [Alex Bowen]. Written in assembly, the game’s engine implements a subset of the Dungeons & Dragons Systems Reference Document (SRD), and is flexible enough that you could use it to produce your own ASCII art role-playing game that can run on either a Model 100 emulator like Virtual-T or on the real hardware.

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Remixed Pi Recovery Kit V2 Offers Another Path

June 12, 2024 by 3 Comments

Just a few months after releasing the long-awaited second version of his Raspberry Pi Recovery Kit, [Jay Doscher] is back with an alternate take on his latest Pi-in-a-Pelican design. This slightly abridged take on the earlier design should prove to be easier and cheaper to assemble for those playing along at home while keeping the compromises to a minimum.

Probably the biggest change is that the Raspberry Pi 5 has been swapped out for its less expensive and more abundant predecessor. The Pi 4 still packs plenty of punch, but since it requires less power and doesn’t get as hot, it’s less temperamental in a build like this. Gone is the active cooling required by the more powerful single-board computer, and the wiring to distribute power to the Kit’s internal components has been simplified. The high-end military style connectors have been deleted as well. They looked cool, but they certainly weren’t cheap.

One of the most striking features of the original Recovery Kit was the front-mounted switches — both the networking type that’s intended to help facilitate connecting the Raspberry Pi to whatever hardware is left after the end of the world, and the toggles used to selectively control power to to accessory devices. Both have returned for the Recovery Kit 2B, but they’re also optional, with blank plates available to fill in their vacant spots.

Ultimately, both builds are fairly similar, but there’s enough changes between the two that it will have a notable impact on how much time (and money…) it would take you create one of your own. [Jay] has attempted to offer less intimidating versions of his designs in the past; while other creators take a “one and done” approach to their projects, he seems eager to go back and rethink problems that most others would have considered solved.

From Nissan ICE Pickup To BEV With Nissan Leaf Heart

June 11, 2024 by 9 Comments
First run of the motor with battery pack still externally connected.

Last year [Jimmy] got a request from a customer ([Dave]) to help convert a 1998 Nissan Frontier pickup into an electric drive vehicle, with a crashed 2019 Nissan Leaf providing the battery and electric motor for the conversion. He has documented the months-long journey with plenty of photos, as well as a series of videos over at the [EVSwap Conversions] YouTube channel. While the idea sounds easy enough, there’s a lot more to it than swapping out the ICE with an electric motor and sticking some batteries to the bottom of the car somewhere with double-sided tape. The pickup truck got effectively stripped down  and gutted, before the 110 kW (150 HP) motor got installed using an adapter plate.

The donor Leaf’s battery pack came in at a decently sized 40 kWh, which should give the converted Nissan Frontier BEV a range of easily 100 miles. This pack was split up into two packs, which got put into a custom aluminium battery box, each mounted on one side of the driveshaft. The charging port got installed on the front of the car, next to the logo, discreetly behind a panel. The front of the car had much of the openings that were needed for the ICE’s radiator sealed up for reduced air friction, along with the new low-friction tires that got installed. Although this converted car still has a radiator, it only needs to assisting cooling the motor stack (including inverter and charger) when driving slowly or charging, making it far less demanding and thus allows for a more sleek front.

As a bonus, the car still has the manual 5-gear shift, just without a clutch, and the pickup bed can now also tilt, albeit with hydraulics (so far). Considering that it started with a decent 1998 pickup and totaled Nissan Leaf, this is among the cleanest conversions we have seen, not to mention a good use of a crashed BEV.

Thanks to [JohnU] for the tip.

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A clipping of the "3D Printing & Modelling" skill tree. An arrow pointing up says "Advanced" and there are several hexagons for various skills on the page including blanks for writing in your own options and some of the more advanced skills like "Print in Nylon or ASA material"

Maker Skill Trees Help You Level Up Your Craft

June 11, 2024 by 12 Comments

Hacking and making are great fun due to their open ended nature, but being able to try anything can make the task of selecting your next project daunting. [Steph Piper] is here with her Maker Skill Trees to give you a map to leveling up your skills.

Featuring a grid of 73 hexagonal tiles per discipline, there’s plenty of inspiration for what to tackle next in your journey. The trees start with the basics at the bottom and progressively move up in difficulty as you move up the page. With over 50 trees to select from (so far), you can probably find something to help you become better at anything from 3D printing and modeling to entrepreneurship or woodworking.

Despite being spoiled for choice, if you’re disappointed there’s no tree for your particular interest (underwater basket weaving?), you can roll your own with the provided template and submit it for inclusion in the repository.

Want to get a jump on an AI Skill Tree? Try out these AI courses. Maybe you could use these to market yourself to potential employers or feel confident enough to strike out on your own?

[Thanks to Courtney for the tip!]

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A C64 SID Replacement With Built-in Games

June 11, 2024 by 9 Comments

Developer [frntc] has recently come up with a smaller and less expensive way to not only replace the SID chip in your Commodore 64 but to also make it a stereo SID! To top it off, it can also hold up to 16 games and launch them from a custom menu. The SIDKick Pico is a simple board with a Raspberry Pi Pico mounted on top. It uses a SID emulation engine based on reSID to emulate both major versions of the SID chip — both the 6581 and the 8580. Unlike many other SID replacements, the SIDKick Pico also supports mouse and paddle inputs, meaning it replaces all functionality of the original SID!

Sound can be generated in three different ways: either using PWM to create a mono audio signal that is routed out via the normal C64/C128 connectors, an external PCM5102A DAC board, or using a different PCB design that has pads for an on-board DAC and TL072 op-amp. While many Commodore purists dislike using replacement chips, the reality is that all extant SID chips were made roughly 40 years ago, and as more and more of them fail, options like the SIDKick Pico are an excellent way to keep the sound of the SID alive.

If you want to hear the SIDKick Pico in action, you can check out the samples on the linked GitHub page, or check out the video below by YouTuber Wolfgang Kierdorf of the RETRO is the New Black channel. To get your hands on a SIDKick Pico, you can follow the instructions on the GitHub page for ordering either bare PCBs or pre-assembled PCBs from either PCBWay or your board manufacturer of choice.

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