Prepare To Brake: Quick Intro To Metal Bending

If you want to bend metal to make shapes, you might use equipment like a brake. But if you don’t have one, no worries. You can still do a lot with common tools like a vise and torches. [Bwrussell] shows you how. He welds together a die to use as a bending jig and makes a set of table legs.

You might think that putting metal in a vise and bending it isn’t exactly brain surgery. It isn’t, but there is more to it than that. Starting with a bending plan and the creation of the jigs, clamping and bending is only part of it. You can see a little bit of the action in the video below.

Speaking of planning, the design was in Fusion 360’s sheet metal workflow. To facilitate the bends, the build uses two torches. A MAPP torch gets very hot, and a propane torch makes sure that a larger area stays hot. There are quite a few tips you can pick up in this post, even if you aren’t making table legs.

Fusion 360 does a lot of the design work, but if you want a quick lesson on what happens when you bend metal, we can help. Want to make your own metal brake?

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Break Free From Proprietary Digital Radio

Digital modes are all the rage these days in amateur radio — hams are using protocols like WSPR to check propagation patterns, FT8 to get quick contacts on many bands with relatively low power, and MSK144 to quickly bounce a signal off of a meteor. There’s also digital voice, which has a number of perks over analog including improved audio quality. However, the major downside of most digital voice modes, at least those in use on UHF and VHF, is that they are proprietary with various radio brands having competing digital standards. To get above the noise a more open standard can be used instead.

The M17 standard, originally created by [Wojciech Kaczmarski] aka [SP5WWP], uses Codec 2 to convert voice into a digital format before it is broadcast over the air. Codec 2 is an open standard unlike other audio codecs. M17 also supports reflectors, which can link individual radios or entire repeaters together over the Internet. While you can make purpose-built modules that will interface with most standard radio inputs, it’s also possible to modify existing hardware to support this standard as well. The video below from [Tech Minds] shows this being done to a radio with only a few hardware modifications and the installation of a new firmware.

For anyone who has been frustrated that there’s no real universal standard for digital voice in VHF and above, M17 could be a game-changer if enough people get tired of their friends being on other proprietary digital systems. There’s plenty of supported hardware out there that most hams probably already have already, including a number of TNC devices like the Mobilinkd and the DigiRig, so it shouldn’t be too hard to get started. If you’re more into networking over radio, though, take a look at this method for sending high-bandwidth IP networking over the UHF band. Continue reading “Break Free From Proprietary Digital Radio”

Repairing A Home Injection Molding Machine

When [Michael] over at the Teaching Tech YouTube channel bought a hobby injection molding machine a long time ago, one of the plans he had with it was to use it for grinding up waste bits of PLA filament for injection molding. Since the machine was bought from a US shop and [Michael] is based in Australia it required some modifications to adapt it to the local 220+ VAC mains, followed by adding a PID temperature controller and a small compressor to provide the compressed air rather than from a large shop compressor.

Although [Michael] had discussed using the machine for PLA with the seller to confirm that this would work, a user error meant that the now defective unit had been sitting idly for many years, until recently.

Since the machine had been gathering dust and rust in the garage, fixing the machine up took a complete teardown to remove corrosion and resolve other issues. After this the original fault was identified, which turned out to be a shorted wire near the heater which had been turned up to a too high temperature, leading to the release of magic smoke and banishment of the machine to the Pit of Despair, AKA the shadowy depths of one’s garage.

In this first installment, [Michael] cleaned up the machine and restored it to a working state. In the next part injection molding will be attempted again, which should give some idea of the feasibility of turning scraps of PLA and failed 3D prints into smooth injection molded parts, assuming you have the CNC machine or patience to carve out the requisite molds, of course.

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3D Print Your Best Friend A Wheelchair

We all know that 3D printing has been a boon for people with different life challenges. But the Ford Motor Company in Mexico wants to help dogs that need mobility assistance. They’ve designed and released P-Raptor (we presume the P is for perro), a wheelchair for pooches with rear leg issues. The web page is in Spanish, and translating it didn’t seem to work for some reason, but if you have any Spanish, you can probably work it out or cut and paste just the text into your favorite translator.

The design is modular to adapt to different size dogs and different problems. It contains an electric motor in the tires. The tires themselves are oversized to help your friend cover rugged terrain. Dogs want to look cool, too, so a grill with lighting is included.

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Voyager 2: Communication Reestablished With One Big Shout

You could practically hear the collective “PHEW!” as NASA announced that they had reestablished full two-way communications with Voyager 2 on Friday afternoon! Details are few at this point — hopefully we’ll get more information on how this was pulled off, since we suspect there was some interesting wizardry involved. If you haven’t been following along, here’s a quick recap of the situation.

As we previously reported, a wayward command that was sent to Voyager 2, currently almost 19 light-hours distant from Earth, reoriented the spacecraft by a mere two degrees. It doesn’t sound like much, but the very narrow beamwidth on Voyager‘s high-gain antenna and the vast distance put it out of touch with the Canberra Deep Space Network station, currently the only ground station with line-of-sight to the spacecraft. While this was certainly a problem, NASA controllers seemed to take it in stride thanks to a contingency program which would automatically force the spacecraft to realign itself to point at Earth using its Canopus star tracker. The only catch was, that system wasn’t set to engage until October.

With this latest development, it appears that mission controllers weren’t willing to wait that long. Instead, based on what was universally referred to in the non-tech media as a “heartbeat” from Voyager on August 1– it appears that what they were really talking about was the use of multiple antennas at the Canberra site to pick up a weak carrier signal from the probe — they decided to send an “interstellar shout” and attempt to reorient the antenna. The 70-m DSS-43 dish blasted out the message early in the morning of August 2, and 37 hours later, science and engineering data started streaming into the antenna again, indicating that Voyager 2 was pointing back at Earth and operating fine.

Hats off to everyone involved in making this fix and getting humanity’s most remote outpost back online. If you want to follow the heroics in nearly real-time, or just like watching what goes on at the intersection of Big Engineering and Big Science, make sure you check out the Canberra DSN Twitter feed.

Rocket Stove Efficiently Heats Water

Rocket stoves are an interesting, if often overlooked, method for cooking or for generating heat. Designed to use biomass that might otherwise be wasted, such as wood, twigs, or other agricultural byproducts, they are remarkably efficient and perform relatively complete combustion due to their design, meaning that there are fewer air quality issues caused when using these stoves than other methods. When integrated with a little bit of plumbing, they can also be used to provide a large amount of hot water to something like an off-grid home as well.

[Little Aussie Rockets] starts off the build by fabricating the feed point for the fuel out of steel, and attaching it to a chimney section. This is the fundamental part of a rocket stove, which sucks air in past the fuel, burns it, and exhausts it up the chimney. A few sections of pipe are welded into the chimney section to heat the water as it passes through, and then an enclosure is made for the stove to provide insulation and improve its efficiency. The rocket stove was able to effortlessly heat 80 liters of water to 70°C in a little over an hour using a few scraps of wood.

The metalworking skills of [Little Aussie Rockets] are also on full display here, which makes the video well worth watching on its own. Rocket stoves themselves can be remarkably simple for how well they work, and can even be built in miniature to take on camping trips as a lightweight alternative to needing to carry gas canisters, since they can use small twigs for fuel very easily. We’ve also seen much larger, more complex versions designed for cooking huge amounts of food.

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If The Shoe Doesn’t Fit, Print It!

Usually when we talk about flip-flops here we mean the circuit. But in this case, it is [Jeandre Groenewald’s] 3D-printed shoe design called Sloffies. The shoes use TPU, and the matching package prints in PLA. Of course, you have to pick the size to fit your feet, and there’s an OpenSCAD file that allows you to customize the strap.

Unlike some 3D apparel we’ve seen, these look like a commerical product. Of course, the cool product packaging doesn’t hurt any. Are they comfortable? We don’t know, but our guess is it is no worse than other similar shoes that are made of one material.

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