CNC On The Desktop Hack Chat

August 24, 2020 by Dan Maloney 6 Comments

Join us on Wednesday, August 26 at noon Pacific for the CNC on the Desktop Hack Chat with Matt Hertel and John Allwine!

Once limited to multi-million dollar machines on the floors of cavernous factories, CNC technology has moved so far downscale in terms of machine size that it’s often easy to lose track of where it pops up. Everything from 3D-printers to laser engravers use computer numeric control to move a tool to some point in three-dimensional space, and do it with unmatched precision and reproducibility.

CNC has gotten so pervasive that chances are pretty good that there’s a CNC machine of some sort pretty close to everyone reading this, with many of those machines being homebrew designs. That’s the backstory of Pocket NC, a company that was literally started in a one-bedroom apartment in 2011 by Matt and Michelle Hertel. After a successful Kickstarter that delivered 100 of their flagship five-axis desktop CNC mills to backers, they geared up for production and now turn out affordable machine tools for the masses. We’ve even seen some very complex parts made on these mills show up in projects we’ve featured.

For this Hack Chat, we’ll be joined by Pocket NC CTO and co-founder Matt Hertel and John Allwine, who recently joined the company as Principal Software Engineer. We’ll discuss not only Pocket NC’s success and future plans, but the desktop CNC landscape in general. Drop by with your questions regarding both the hardware and the software side of CNC, about turning an idea into a business, and where the CNC world and next-generation manufacturing will be heading in the future.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, August 26 at 12:00 PM Pacific time. If time zones baffle you as much as us, 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.

Eavesdropping On Satellites For Fun And Profit

August 20, 2020 by Dan Maloney 8 Comments

Geosynchronous satellites, girdling the Earth from their perches 36,000 km above the equator, are remarkably useful devices. Depending on where they’re parked, they command views of perhaps a third of the globe at a time, making them perfect communications relays. But as [James Pavur] points out in his DEF CON Safe Mode talk, “Whispers Among the Stars”, geosynchronous satellite communication links are often far from secure.

[James], a D. Phil. student in Systems Security at Oxford University, relates that his exploits rely on the wide areas covered by the downlink signals from the satellites, coupled with security as an afterthought, if it was even thought of at all by satellite service providers. This lackadaisical approach let him use little more than a regular digital satellite TV dish and a tuner card for a PC — off-the-shelf stuff that you’d really have to try hard to spend more than $300 on — to tap into sensitive information.

While decoding the digital signals from satellites into something parseable can be done with commercial applications, [James] and his colleagues built a custom tool, GSExtract, to pull data from the often noisy signals coming down from on high. The setup returned an amazing bounty of information, like maritime operators relaying the passport information of crew members from ship to shore, point-of-sale terminal information from cruise ships in the Mediterranean, and in-flight entertainment systems in jet airliners. The last example proved particularly alarming, as it revealed an exploitable connection between the systems dedicated to keeping passengers content and those in the cockpit, which clearly should not be the case.

We found [James’] insights on these weaknesses in satellite communications fascinating, and it’s well worth the 45 minutes to watch the video below and perhaps try these exploits, which amount to side-channel attacks, for yourself.

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Analyzing Water Quality With A Pair Of Robots

August 14, 2020 by Tom Nardi 2 Comments

To adequately study a body of water such as a lake, readings and samples need to be taken from an array of depths and locations. Traditionally this is done by a few researchers on a small boat with an assortment of tools that can be lowered to the desired depth, which is naturally a very slow and expensive process. As the demand for ever more granular water quality analysis has grown, various robotic approaches have been suggested to help automate the process.

A group of students from Northeastern University in Boston have been working on Project Albatross, a unique combination of semi-autonomous vehicles that work together to provide nearly instantaneous data from above and below the water’s surface. By utilizing open source software and off-the-shelf components, their system promises to be affordable enough even for citizen scientists conducting their own environmental research.

The surface vehicle, assembled from five gallon buckets and aluminum extrusion, uses a Pixhawk autopilot module to control a set of modified bilge pumps acting as thrusters. With ArduPilot, the team is able to command the vehicle to follow pre-planned routes or hold itself in one position as needed. Towed behind this craft is a sensor laden submersible inspired by the Open-Source Underwater Glider (OSUG) that won the 2017 Hackaday Prize.

Using an array of syringes operated by a NEMA 23 stepper motor, the glider is able to control its depth in the water by adjusting its buoyancy. The aluminum “wings” on the side of the PVC pipe body prevent the vehicle from rolling will moving through the water. As with the surface vehicle, many of the glider components were sourced from the hardware store to reduce its overall cost to build and maintain.

The tether from the surface vehicle provides power for the submersible, greatly increasing the amount of time it can spend underwater compared to internal batteries. It also allows readings from sensors in the tail of the glider to be transmitted to researchers in real-time rather than having to wait for it to surface. While the team says there’s still work to be done on the PID tuning which will give the glider more finely-grained control over its depth, the results from a recent test run already look very promising.

A High Torque Gearbox You Can Print At Home

August 13, 2020 by Lewin Day 10 Comments

Typically, when we think of 3D printed parts, we think of unique parts with complex geometries that would be hard to fabricate with other techniques. Strength is rarely the first thing that comes to mind, due to the limitations of thermoplastics and the problem of delamination between layers. However, with smart design, it’s possible to print parts capable of great feats, just as [Brian]’s high-torque gearbox demonstrates.

Pulling a car is a great way to show off the strength of your build.

The gearbox consists of entirely 3D-printed gears, along with the enclosure, with the only metal parts being a few bearings and shafts. Capable of being produced out of PLA on a regular FDM printer, [Brian] has successfully tested the gearbox up to 132 kg∗cm. The suspicion is that there may be more left in it, but some slippage was noticed in the gear train when trying to tow a Ford Focus with the handbrake still on.

Even better, with the addition of a potentiometer, the gearbox can be used as an incredibly tough servo. [Brian] demonstrates this by lifting 22 kg at a distance of 6 cm from the center of the output shaft. The servo does it with ease, though eventually falls off the bench due to not being held down properly.

It’s a build that shows it’s possible to use 3D-printed parts to do some decently heavy work in the real world, as long as you design appropriately. [Brian] does a great job of explaining what’s involved, discussing gear profile selection and other design choices that affect the final performance. We’ve seen similar work from others before, too. Video after the break.

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A Tetraquark For Muster Mark!

August 13, 2020 by Moritz v. Sivers 19 Comments

The holy grail of every particle physics experiment is the discovery of a new particle. Finding a new constituent of matter may earn you eternal glory within the history of physics. Unfortunately, since the last missing piece of the Standard Model, the Higgs boson, was discovered in 2012, and with still no clue about the nature of dark matter and dark energy, there is not much hope to stumble upon a new fundamental building block of matter any time soon.

Luckily, this is not true for composite particles, especially the strange world of quark matter still yields some potential for new discoveries. The latest of such was the observation of a new tetraquark by the LHCb experiment. But what the hell is a quark anyway and why is it named after a German dairy product? Continue reading “A Tetraquark For Muster Mark!” →

Under Pressure: How Aluminum Extrusions Are Made

August 13, 2020 by Dan Maloney 50 Comments

At any given time I’m likely to have multiple projects in-flight, by which of course I mean in various stages of neglect. My current big project is one where I finally feel like I have a chance to use some materials with real hacker street cred, like T-slot extruded aluminum profiles. We’ve all seen the stuff, the “Industrial Erector Set” as 80/20 likes to call their version of it. And we’ve all seen the cool projects made with it, from CNC machines to trade show displays, and in these pandemic times, even occasionally as sneeze guards in retail shops.

Aluminum T-slot profiles are wonderful to work with — strong, lightweight, easily connected with a wide range of fasteners, and infinitely configurable and reconfigurable as needs change. It’s not cheap by any means, but when you factor in the fabrication time saved, it may well be a net benefit to spec the stuff for a project. Still, with the projected hit to my wallet, I’ve been looking for more affordable alternatives.

My exploration led me into the bewilderingly rich world of aluminum extrusions. Even excluding mundane items like beer and soda cans, you’re probably surrounded by extruded aluminum products right now. Everything from computer heatsinks to window frames to the parts that make up screen doors are made from extruded aluminum. So how exactly is this ubiquitous stuff made?

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Miniature Star Wars Arcade Lets You Blow Up The Death Star On The Go

August 12, 2020 by Tom Nardi 10 Comments

If you have fond childhood memories of afternoons spent at the local arcade, then you’ve had the occasional daydream about tracking down one of those old cabinets and putting it in the living room. But the size, cost, and rarity of these machines makes actually owning one impractical for most people.

While this fully functional 1/4th scale replica of the classic Star Wars arcade game created by [Jamie McShan] might not be a perfect replacement for the original, there’s no denying it would be easier to fit through your front door. Nearly every aspect of the iconic 1983 machine has been carefully recreated, right down to a working coin slot that accepts miniature quarters. Frankly, the build would have been impressive enough had he only put in half the detail work, but we certainly aren’t complaining that he went the extra mile.

[Jamie] leaned heavily on resin 3D printed parts for this build, and for good reason. It’s hard to imagine how he could have produced some of the tiny working parts for his cabinet using traditional manufacturing techniques. The game’s signature control yoke and the coin acceptor mechanism are really incredible feats of miniaturization, and a testament to what’s possible at the DIY level with relatively affordable tools.

The cabinet itself is cut from MDF, using plans appropriately scaled down from the real thing. Inside you’ll find a Raspberry Pi 3 Model A+ running RetroPie attached directly to the back of a 4.3 inch LCD with integrated amplified speakers. [Jamie] is using an Arduino to handle interfacing with the optical coin detector and controls, which communicates with the Pi over USB HID. He’s even added in a pair of 3,000 mAh LiPo battery packs and a dedicated charge controller so you can blow up the Death Star on the go.

Still don’t think you can fit one in your apartment? Not to worry, back in 2012 we actually saw somebody recreate this same cabinet in just 1/6th scale.

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