Design For 3D Printing Hack Chat

May 22, 2023 by No comments

Join us on Wednesday, May 24 at noon Pacific for the Design for 3D Printing Hack Chat with Eric Utley!

Like a lot of enabling technologies, 3D printing has had a strange trajectory. It started out as a laboratory oddity, moved on to industrial applications, and finally filtered down to the DIY set, first as scratch-built machines and later as inexpensive commodity printers that can be found almost anywhere. Pretty much everyone who needs a 3D printer now has one.

Not all additive manufacturing technologies are created equal, though, and there are plenty of applications for 3D printed parts where FDM just won’t cut it. Luckily, any of us can get access to the latest and greatest manufacturing technologies through job houses that specialize in everything from metal 3D printing to sheet metal fabrication, CNC machining, and even small-run injection molding. We may not be able to afford any of the machines, but in a lot of cases we can afford to rent time of them and get high-quality parts quickly.

join-hack-chatBut that raises another question: Is my design ready for printing? What works on an Ender on your shop bench might not quite translate to the latest SLS printer, and sending off an iffy design could just end up wasting time and money. Whether you’re sending your designs out and running them up on your own printer, you want to know what you’re doing will work. That’s why we’ve asked Eric Utley, an applications engineer with Protolabs, to stop by the Hack Chat. With 12 years of additive manufacturing experience, he’ll be able to help you tune up your designs and make sure they’re ready to print.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, May 24 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.

Hoverboard Rides On Eddy Currents

May 22, 2023 by 32 Comments

The famous hoverboards of Back to the Future haven’t quite gotten here yet, but that hasn’t stopped anyone with a unique personal vehicle from using the name any time they need some quick marketing. The self-balancing scooter trend of the mid-2010s was the best example of this in recent memory, but there are also water-propelled platforms that use the popular name as well as a myriad of other more skateboard-like devices that never got off the ground at all. This project from [Damien Dolata], on the other hand, might be the most authentic prototype we’ve seen compared against the fictional version presented in the movie.

The hoverboard uses a set of rotating magnets, referred to in this build as magneto-rotational repulsors, which spin up to an extremely high rotational speed underneath the board. When above a metal surface, the spinning magnets generate eddy currents in the metal beneath them which create the strong magnetic field needed to levitate the board. Unlike the Lexus hoverboard system which used supercooling magnets, this is a much more affordable way of producing magnetic fields but is a little bit more complicated due to the extra moving parts.

As this is still in the prototyping stages, it has only been able to lift around 30 kg and hasn’t been tested in motion yet, but there are two small turbines built into the hoverboard to generate thrust whenever [Damien] gets to that point. It would require a larger metal surface to move across as well, which might be the main reason why it hasn’t been tested this way yet. For any native French speakers taking a look at this project, be sure to fill in any of our gaps in the comments below, and for other ways that eddy currents have been used in transportation take a look at this bicycle that uses them in its drivetrain.

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Active Racing Simulator Pedal

May 17, 2023 by 11 Comments

Racing virtual cars from behind a PC monitor might be cheaper than doing it in the real world, but high-end sim racing peripherals still come with high-end prices. With the increasing popularity of force-feedback pedals [Tristan Fenwick] built built an active pedal that can provide significant resistance.

[Tristan] integrated a load cell into the 3D printed pedal linkage, which is connected to a 130 W NEMA23 servo motor via a 8 mm lead screw. With constant feedback from the load cell, a simple PID controller running on an Arduino to actively adjust the pedal’s position and the amount of resistance it provides.

At ~$250 in parts, it’s a significantly more affordable than the $2300 price tag on a single Simucube pedal, which served as inspiration for this project. There are still some issues to address, such as shaky ADC readings and a lack of computing power on the Arduino, the demo video after the break looks incredibly promising. [Tristan] also notes that 300 kg is overkill and a slightly smaller servo motor would probably also work.

For more incredible simulator inspiration, check out the A-10 Warthog cockpit, a 3D printed flight sim yoke and pedals, and a tank driving simulator from before the age of computer graphics.

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Industrial Robot Gets Open-Source Upgrade

May 14, 2023 by 15 Comments

Industrial robots are shockingly expensive when new, typically only affordable for those running factories of some sort. Once they’ve gone through their life cycle building widgets, they can be purchased for little more than scrap value, which is essentially free compared to their original sticker price. [Excessive Overkill] explains all of this in a video where he purchased one at this stage to try to revive, but it also shows us how to get some more life out of these robots if you can spend some time hunting for spare parts, installing open-source firmware, and also have the space for a robot that weighs well over a thousand kilograms.

This specific robot is a Fanuc R2000ia with six degrees of freedom and a reach of over two meters. Originally the plan was to patch together a system that could send modern gcode to the Fanuc controller, but this was eventually scrapped when [Excessive Overkill] realized the controller that shipped with this robot was for an entirely different machine and would never work. Attempts to find upgraded firmware were frustrated, and after a few other false starts a solution was found to get the robot working again using LinuxCNC and Mesa FPGA cards, which have built-in support for Fanuc devices like this.

More after the break…

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Hackaday Prize 2023: Meet The Ten Re-Engineering Education Finalists

May 11, 2023 by 31 Comments

They say time flies when you’re having fun, and doubly so when you’re hacking hardware. If you can believe it, we’ve already closed out the first challenge of the 2023 Hackaday Prize, and you know what that means — it’s time to announce the 10 finalists.

As a reminder, each of these projects not only takes home $500 USD, but moves on to the next round of judging. During the recently announced 2023 Supercon, we’ll announce the six projects that were selected by our panel of judges to collect their share of $100,000 in prize money– plus a residency at Supplyframe’s DesignLab and eternal hacker glory for the Grand Prize winner.

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Jump Like Mario With This Weighted Wearable

May 11, 2023 by 5 Comments

Virtual reality has come a long way in the past decade, with successful commercial offerings for gaming platforms still going strong as well as a number of semi-virtual, or augmented, reality tools that are proving their worth outside of a gaming environment as well. But with all this success they still haven’t quite figured out methods of locomotion that feel natural like walking or running. One research group is leaping to solve one of these issues with JumpMod: a wearable device that enhances the sensation of jumping.

The group, led by [Pedro Lopes] at the University of Chicago, uses a two-kilogram weight worn on the back to help provide the feeling of jumping or falling. By interfacing it with the virtual reality environment, the weight can quickly move up or down its rails when it detects that the wearer is about to commit to an action that it thinks it can enhance. Wearers report feeling like they are jumping much higher, or even smashing into the ground harder. The backpack offers a compact and affordable alternative to the bulky and expensive hardware traditionally used for this purpose.

With builds like these, we would hope the virtual reality worlds that are being created become even more immersive and believable. Of course that means a lot more work into making other methods of movement in the virtual space feel believable (like walking, to start with) but it’s an excellent piece of technology that shows some progress. Augmenting the virtual space doesn’t always need bulky hardware like this, though. Take a “look” at this device which can build a believable virtual reality space using nothing more than a webcam.

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OScope Advert From 1987 Rocks It

May 11, 2023 by 31 Comments

We can’t remember ever seeing a late-night TV ad for oscilloscopes before but, for some reason, Tektronix did produce a video ad in 1987. You can see it below and enjoy the glorious music and video production standards of the 1980s.

We assume this was made to show at some trade show or the like. Even if there was a Home Shopping Network in 1987, we doubt many of these would have been sold despite the assertion they were “low cost” — clearly a relative term in this case.

You’ve got to wonder if the narrator understood what he was saying or if he was just reading from a script. Pretty impressive either way. We loved these old scopes, although we also like having very capable scopes that don’t strain our backs to lift.

On the bright side, these scopes today are pretty affordable on the used market if you can find one that doesn’t need a repair with an exotic part. For example, we found several 2221s or 2221As for under $200 without looking hard. The shipping, of course, could potentially almost double the price.

While you can get a modern scope for $200, it probably isn’t the same quality as a Tektronix. Then again, the new scope won’t have CRTs and exotic Tektronix parts to wear out, either. Picking a scope is a pretty personal affair, though, so one person’s great scope might be another person’s piece of junk.

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