3D Printed V8 Engine Uses Solenoids

November 25, 2018 by Al Williams 17 Comments

Normally when you think of a V8 engine you think of pistons driven by exploding fuel, pushing a crankshaft. [Miller’s Planet’s] version doesn’t use pistons, instead it uses solenoids along with a 3D printed crankshaft. The finished product would make a great science project or classroom demonstration of how a crankshaft converts a reciprocal linear motion into a rotary motion.

There are a lot of 3D printed parts and the links are in the post. A lot of the video (see below) is filmed in the wordless-workshop style with just a few text overlays to explain what is happening. But towards the middle, you’ll hear an explanation of how a solenoid produces force. The real payoff though is at the end, when you get to watch the contraption in motion.

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The Best Laptop Gets Even Better

November 24, 2018 by Brian Benchoff 85 Comments

The ThinkPad is the greatest laptop ever created. It doesn’t come in rose gold, it comes in black. It doesn’t have a weird screen instead of an escape key. For less than half the price of a MacBook, you can have a capable laptop that will somehow fit three drives inside. It’s madness, but it’s still not the perfect tool for hacking. To get there, you’re going to need to load that thing up with an independent Linux system, and maybe a solderless breadboard. That’s what [ollie242] is doing with his ThinkPad, and the results are the perfect addition to the perfect laptop.

This build is really just a 3D printed drive caddy for the Thinkpad UltraBay, the modular standard that allows you to add a CD drive, SATA drive, or even a serial and parallel port to your laptop. [ollie242] is modeling this off the CD drive taken from a ThinkPad T420, so we’re looking at a ‘Serial Ultrabay Enhanced’ version of this standard, which is compatible with a T430, which is still the best laptop you can possibly buy.

Inside this 3D printed drive caddy is a Raspberry Pi Zero W, powered by the ThinkPad through the internal SATA connector. The Pi Zero has right-angle headers attached, giving access to the GPIO pins from the outside. Just to add a little flair, [ollie242] added an OLED display to show the IP address, the CPU load, and the memory availability of the Pi.

This is a great project, if only because no one has any use for a CD drive anymore. Since these UltraBay drives are huge, it would be a simple matter to add a much more powerful computer to the drive like the recently announced Raspberry Pi 3 Model A+. There are — or at least there should be — some interesting internal connections on that UltraBay port, and it’s not inconceivable this Raspberry Pi UltraBay could be used as a coprocessor of sorts for its host laptop.

Put That DLP Printer To Use Making PCBs

November 24, 2018 by Tom Nardi 38 Comments

Now that these DLP printers are cheaper and more widely available, we’re starting to see hackers poking around the edge of the envelope to see what else the machines are capable of. [Electronoobs] recently got his hands on a couple of these printers, and thought he would do some experiments with using them for PCB production.

Rather than extruding molten plastic, these printers use light to cure resin layer-by-layer. In theory if the printer is good enough to cure the light-activated resin for a high resolution print, it should be able to do much the same thing with photosensitive PCBs.

Unfortunately, getting an STL out of a PCB design program takes a few intermediary steps. In the video after the break, [Electronoobs] shows his workflow that takes his design from EasyADA and turning it into a three dimensional object the DLP printer will understand. He does this with Blender and it looks pretty straightforward, but in the past we’ve seen people do similar tricks with Inkscape if that’s more your style.

Once you’ve grafted another dimension onto your PCB design, you may need to scale it to the appropriate size. [Electronoobs] notes that his STL for a 60 mm wide PCB came out of Blender as less than 2 mm wide, so you might need to break out the dreaded mathematics to find the appropriate scale value. Once the dimensions look good, you can load this file up into the printer as you would any normal print.

On the printer side of things, [Electronoobs] manually laminates UV photoresist film onto some copper clad boards with an iron, but you could skip this step and buy pre-sensitized boards as well. In any event, you drop the board where the UV resin normally goes, press the print button, and wait about ten minutes. That should give it enough time to expose the board, and you then proceed with the normal washing and acid bath process that hackers have been doing since time immemorial.

As [Electronoobs] shows, the results are quite impressive. While this still won’t make it any easier for you to do double-sided PCBs in the home lab, it looks like a very compelling method for producing even SMD boards with relative ease. This isn’t the first time somebody has tried using a DLP printer to run off some PCBs, but now that the technology has matured a bit it looks like it’s finally becoming practical.

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Disco Ain’t Dead: Blinky Ball Makes You Solder Inside A Dome

November 22, 2018 by Mike Szczys 10 Comments

Disco balls take a zillion mirrors glued to a sphere and shine a spotlight on them. But what if the ball itself was the light source? Here’s a modern version that uses addressable LEDs in a 3D-printed sphere that also hides the electronics inside the ball itself.

Check out the video below to see the fantastic results. It’s a Teensy 3.6 driving a whopping 130 WS2812 LEDs to make this happen. (Even though the sphere has the lowest surface area to volume ratio.) There’s even a microphone and an accelerometer to make the orb interactive. Hidden inside is a 4400 mAh battery pack that handles recharging and feeds 5 V to the project.

For us, it’s the fabrication that really makes this even more impressive. The sphere itself is 3D printed as four rings that combine to form a sphere. This makes perfect spacing for the LEDs a snap, but you’re going to spend some time soldering the voltage, ground, and data connections from pixel to pixel. In this case that’s greatly simplified because the LEDs were sourced from AliExpress already hosted on a little circle of PCB so you’re not trying to solder on the component itself. Still, that’s something like 390 wires requiring 780 solder joints!

We love seeing an LED ball you can hold in your hand. But if you do want something bigger, try this 540 LED sphere built from triangular PCBs.

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PLA Foils Homemade Tachometer

November 22, 2018 by Al Williams 19 Comments

[Integza] built a Tesla turbine and wanted to know how fast it was spinning. However, he didn’t have a tachometer, and didn’t want to buy one. After a false start of trying to analyze the audio to measure the speed, he decided to use a tried-and-true method. Let the wheel break an infrared (IR) optointerruptor and count the spokes of the wheel as they go by. If you know the spacing between the spokes, you can compute the speed. There was only one problem: it didn’t work.

Turns out, PLA is at least somewhat transparent to IR. Knowing that it was a simple matter to fix some tape to the wheel that would block IR and that made things work much better. If you missed the video where he built the turbine, you might want to watch it first.

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3D Printer Warning: Heating Plastic To High Temps Is Not Healthy

November 21, 2018 by Bryan Cockfield 42 Comments

If you’ve ever tried to cut a piece of acrylic with a tool designed to cut wood or metal, you know that the plastic doesn’t cut in the same way that either of the other materials would. It melts at the cutting location, often gumming up the tool but always releasing a terrible smell that will encourage anyone who has tried this to get the proper plastic cutting tools instead of taking shortcuts. Other tools that heat up plastic also have this problem, as Gizmodo reported recently, and it turns out that the plastic particles aren’t just smelly, they’re toxic.

The report released recently in Aerosol Science and Technology (first part and second part) focuses on 3D printers which heat plastic of some form or other in order to make it malleable and form to the specifications of the print. Similar to cutting plastic with the wrong tool, this releases vaporized plastic particles into the air which are incredibly small and can cause health issues when inhaled. They are too small to be seen, and can enter the bloodstream through the lungs. The study found 200 different compounds that were emitted by the printers, some of which are known to be harmful, including several carcinogens. The worst of the emissions seem to be released when the prints are first initiated, but they are continuously released throuhgout the print session as well.

Perhaps it’s not surprising that aerosolized plastic is harmful to breathe, but the sheer magnitude of particles detected in this study is worth taking note of. If you don’t already, it might be good to run your 3D printer in the garage or at least in a room that isn’t used as living space. If that’s not possible, you might want to look at other options to keep your work area safe.

Thanks to [Michael] for the tip!

Generative Design Algorithms Prepare For Space

November 17, 2018 by Roger Cheng 14 Comments

NASA is famously risk-averse, taking cautious approaches because billions of taxpayer dollars are at stake and each failure receives far more political attention than their many successes. So while moving the final frontier outward requires adopting new ideas, those ideas must first prove themselves through a lengthy process of risk-reduction. Autodesk’s research into generative design algorithms has just taken a significant step on this long journey with a planetary lander concept.

It was built jointly with a research division of NASA’s Jet Propulsion Laboratory, the birthplace of many successful interplanetary space probes. This project got a foot in the door by promising 30% weight savings over conventional design techniques. Large reduction in launch mass is always a good way to get a space engineer’s attention! Mimicking mother nature’s evolutionary process, these algorithms output very organic looking shapes. This is a relatively new approach to design optimization under exploration by multiple engineering software vendors. Not just Autodesk’s “Generative Design” but also “Topology Optimization” in SolidWorks, plus others. Though these shapes appear ideally suited to 3D printing, Autodesk also had to prove their algorithm could work with more traditional fabrication techniques like 5-axis CNC mills.

This is leading-edge research technology though some less specialized, customer-ready versions are starting to trickle out of research labs. Starting with an exclusive circle: People with right tiers of SolidWorks license, the paid (not free) tier of Autodesk Fusion 360, etc. We’ve looked at another recent project with nontraditional organic shapes, and we’ve looked at generative designs used for their form as well as their function. This category of CAD tools hold a lot of promise, and we’re optimistic they’ll soon become widely accessible so we can all put them to good use in our earthbound projects.

Possibly even before they fly to another planet.

[via Engadget]