3D Printing With Nylon For A More Useful Objects

May 22, 2012 by 34 Comments

[taulman] over on Instructables has been working on his own version of a 3D printer. Unlike the usual PLA or ABS filament all the RepRaps and Makerbots use, this printer uses nylon to make parts with very interesting properties.

Most extrusion printers are designed to print with ABS (a very hard plastic that melts around 220-230° C) or PLA (a somewhat softer plastic that melts at about 180° C). [taulman] is using Nylon 6, a very slippery and bendable plastic that melts around 320° C (about 600 degrees Fahrenheit). He’s doing this with a hot end of his own design and a ‘spiky’ extruder bolt that allows high-temperature thermoplastics to be extruded into any shape imaginable.

For the longest time, the 3D printer community has been using low-temperature thermoplastics such as PLA and ABS. There are obvious benefits to these materials: it’s pretty easy to source a spool of filament, and the low melting point of these plastics makes building a printer easier and safer. Now that [taulman] has the high-temperature plastic nut cracked, he’s moving on to easily-machiniable Delrin and transparent Polycarbonate. Very cool, and hopefully in a year’s time we’ll have a choice of what material to run in our printers.

After the break, there are a few videos [taulman] put up showing his printer at work and the properties of his 3D printed objects. It looks like [taulman] can print objects that are impossible on any other 3D printer we’ve seen; the flexible iPhone case probably couldn’t be made on any other DIY machine.

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Volt Teardown Shows More Than Just What’s Under The Hood

May 22, 2012 by 31 Comments

The Chevrolet Volt is one of the top contenders in mass-market electric vehicles. Now you can get a look at the components that make up the electrical system with this Chevy Volt teardown article.

The adventure starts with a look at the 288 cell battery. It forms a T shape and takes up the space that forms the hump down the center of the interior of a vehicle. Theses have a liquid cooling system build into the enclosure to make sure things don’t get too hot during use or charging. The sights are then set on the control and monitoring hardware, and there’s a lot of it. In fact, the image above is an overview of the eighteen modules that pull the new plug-in EV technology together. If you’re brave enough to void the warranty on one of these, this should be a helpful road map to get you started.

Has anyone seen a teardown of the home charging station for one of these?

Man, Stranded In The Desert, Makes A Motorcycle From His Broken Car

May 21, 2012 by 190 Comments

The original story is in French, and the Google translate is very rough. Please forgive us if we don’t get this completely accurate.

While traveling through the desert somewhere in north west Africa in his Citroen 2CV , [Emile] is stopped, and told not to go any further due to some military conflicts in the area. Not wanting to actually listen to this advice, he decides to loop around, through the desert, to circumvent this roadblock.

After a while of treading off the beaten path, [Emile] manages to snap a swing arm on his vehicle, leaving him stranded. He decided that the best course of action was to disassemble his vehicle and construct a motorcycle from the parts. This feat would be impressive on its own, but remember, he’s still in the desert and un-prepared. If we’re reading this correctly, he managed to drill holes by bending metal and sawing at it, then un-bending it to be flat again.

It takes him twelve days to construct this thing. There are more pictures on the site, you simply have to go look at it. Feel free to translate the labels and post them in the comments.

Update: From [Semicolo] in the comments

You got the translation right, but there’s not just a swing arm that’s broken, there’s a frame beam broken too (not sure about the exact term, one of the 2 girder of the chassis).
He’s not far away but he has a lot of tools and other hardware that could be stolen if he leaves them unattended.

[via Reddit]

Heliowatcher Positions Solar Panels For Highest Efficiency

May 21, 2012 by 17 Comments

[Jason Wright] and [Jeremy Blum] are showing off the project they developed for their Designing with Microcontrollers course at Cornell University. They call it the Heliowatcher, and if you know your Greek mythology we’d be you figured out this watches the movement of the sun and adjust a solar panel to follow it.

Their design is simple and effective. The base is mounted like a Lazy Susan, able to pivot on the horizontal plane. The bottom edge of the solar panel is mounted with two door hinges, with a motorized screw jack used to raise and lower it. The system uses a GPS to provide geographical position, day, and time feedback. This is used in conjunction with an array of four LEDs to determine the best position of the panel. Those LEDs are acting as light sensors; when the top and the bottom detect similar levels, the panel is at its most efficient orientation. The left and right LED sensors work the same way.

Now if we can just work out a self-cleaning system to keep the panels free of the dirty film that builds up over time we’d be set!

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FTA Dish Used To Receive L-band Amateur Radio

May 21, 2012 by 11 Comments

[David Prutchi] has an FTA (free-to-air) satellite dish. This means he can tune and watch freely available satellite television feeds. But this sounds much better than it actually is. There isn’t much that’s broadcasted unecrypted from satellites with the exception of a collection of religious channels. But he still uses the dish by using the FTA satellites to calibrate the alignment, then repositioning it to receive L-Band radio transmissions with his own add-on hardware. In the image above it’s the spiral of wire attached to the dish’s collector.

The satellite transmissions are picked up on the KU-band by an aftermarket horn that [David] purchased for this purpose. To add his own helix receiver he cut a square mounting plate that fits around the horn. This plate serves as a reflector and ground plane, and also hosts the helix connector which picks up the L-band transmissions. He had to be creative with routing the first few inches of the helix but it looks like he manages to get some pretty good performance out of the hardware.

[via Hacked Gadgets]

Hackerspace Intro: STGO Makerspace In Santiago, Chile

May 21, 2012 by 13 Comments

[Roy MacDonald] sent in a few links to all the cool stuff his home base – the StgoMakerSpace (Google translation) in Santiago, Chile – is putting together. They’re a new hackerspace that’s only been open for two months or so, but already they’re put together a great assemblage of tools, hosted a few awesome workshops, and even gotten a good bit of local media exposure.

The StgoMakerSpace found its first bit of fame with a very in-depth article in Qué Pasa, a Chilean magazine (Google Translate). There’s a lot of very, very talented people at StgoMakerSpace that includes [macapola], an industrial designer who spent a year in China learning all about modern, global  manufacturing processes.

StgoMakerSpace has a few workshops coming up, including a Kinect hacking workshop, and Arduino workshop, and a welding workshop. If you’re around Santiago, it’s worth checking out. In addition to very, very smart people and a whole bunch of tools, StgoMakerSpace also has a retro video game museum and FREE BEER brewed in-house.

As a small aside, [Roy] tells us the word ‘hacker’ has a negative connotation in Spanish, and it immediately associated with cybercrime; that’s the reason it’s the Santiago Makerspace. In our experience, the same connotation sometimes applies in English, something that hasn’t stopped all the Hackerspaces around the US.

Salvaged LCD Screen Hacking

May 21, 2012 by 17 Comments

You can find all kinds of LCD screens in broken electronics. But it’s often a chore to figure out how they are controlled if you don’t have a working device that can be used to sniff the communications protocol. [Justin] grabbed this character LCD screen from an old Brother printer and decided to see if he could reuse it in his own projects. Luckily the driver card still worked so he patched into the LCD’s control lines and sniffed the signals when the printer is powered on.

He used the OpenBench Logic Sniffer for this project. It easily captured the data, and also provided analysis tools. The SPI analyzer managed to decode the command signals and message of “Please wait” that pops up at power up. After a bit of folly with the pin out of the display, he is now able to control it thanks to an Arduino library which he wrote. Check out the demo after the break to seem him scrolling through a bunch of different functions for the device.

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