3D-Printed Thermite Brings The Heat, And The Safety

September 10, 2020 by Kristina Panos 15 Comments

Thermites are a double-edged sword. Packing a tremendous energy density, and eager to produce tremendous heat when ignited, thermite is great for welding train tracks. But sometimes you might be looking for a little more finesse. A new approach to 3D printing thermites might just be able to tame the beast.

Most of us do our soldering while sitting safely indoors in a comfortable climate. The biggest dangers we’re likely to face are burnt fingertips, forgetting the heat shrink, or accidentally releasing the smoke monster. But outside of our homes and workshops, there’s a lot of extreme joining of metals going on. No matter where it’s done, welding and brazing in the field requires a lot of equipment, some of which is unwieldy and even more difficult to move around in harsh conditions.

Welding railroad tracks with thermite. Image via YouTube

The utility of brazing is limited by all the complex scaffolding of hardware required to support it. This limiting factor and the discovery of thermite led to exothermic welding, which uses an energetic material to provide enough heat to melt a filler metal and join the pieces. Energetic materials can store a lot of chemical energy and forcefully release it in a short period of time.

Thermites are made of metal oxide and metal powder, often iron oxide and aluminium. When ignited by a source of high heat, thermite compounds undergo an exothermic reduction-oxidation (redox) reaction as the aluminium reduces the number of electrons in the iron oxide atoms. More heat makes the reaction run faster, generating more heat, and so on. The result is molten iron and aluminium oxide slag.

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A 3D Printed Magnetic Stirrer For Your DIY Chemistry Projects

September 3, 2020 by Lewin Day 20 Comments

When mixing or agitating delicate solutions in the chemistry lab, a magnetic stirrer is often the tool of choice. They’re able to be easily sterilized and cleaned, while maintaining isolation between the mechanical parts and the solutions in question. While they can be purchased off the shelf, [Max Siebenschläfer] whipped up a design that can easily be built at home.

The build consists of a 3D printed base, containing a simple brushed motor. This is hooked up to a motor controller fitted with a simple potentiometer for adjusting the speed of rotation. The motor is then fitted with a small 3D printed spinner containing two magnets. A similar 3D printed part acts as a stirrer, and is fitted with a matching pair of magnets, and dropped into the solution. The magnets in the stirrer are attracted to the ones on the end of the motor, and so when the motor spins, the stirrer spins in the solution, with no physical contact required.

It’s a simple way to build a magnetic stirrer at home without having to shell out big money for a laboratory grade unit. We imagine this could be put to fun use for stirring coffee or cocktails, too – if built with a food-grade spinner. More advanced designs are also possible for the eager home scientist. Video after the break.

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Potential Contenders For Battery Supremacy

September 1, 2020 by Lewin Day 47 Comments

Lithium ion batteries have been a revolutionary technology. Their high energy and power density has made the electric car a practical reality, enabled grid storage for renewable energy, and put powerful computers in the palm of the hand. However, if there’s one thing humanity is known for, it’s always wanting more.

Potential contenders for the title of ultimate battery technology are out there, but it will take a major shift to dethrone lithium-ion from the top of the tree.

Dominant For Good Reason

Lithium-ion batteries were first developed by Stanley Whittingham, working at Exxon, who were looking to diversify away from oil in the midst of the major energy crises of the 1970s. Over the years, the technology was developed further, with work by John Goodenough (a superb hacker name if we’ve ever heard one) and Akira Yoshino increasing performance with improved cathode and anode materials. Commercialization was first achieved by Keizaburo Tozawa, working at Sony to develop a better battery for the company’s line of camcorders. Continue reading “Potential Contenders For Battery Supremacy” →

Lithium Sulfur Batteries Slated For Takeoff

August 23, 2020 by Al Williams 60 Comments

Spectrum recently published a post on a new lithium sulfur battery technology specifically targeting electric aviation applications. Although lots of electric vehicles could benefit from the new technology, airplanes are especially sensitive to heavy batteries and lithium-sulfur batteries can weigh much less than modern batteries of equivalent capacity. The Spectrum post is from Oxis Energy who is about to fly tests with the new batteries which they claim have twice the energy density of conventional lithium-ion batteries. The company also claims the batteries are safer, which is another important consideration when flying through the sky.

The batteries have a cathode comprised of aluminum foil coated with carbon and sulfur — which avoids the use of cobalt, a cost driver in traditional lithium cell chemistries. The anode is pure lithium foil. Between the two electrodes is a separator soaked in an electrolyte. The company says the batteries go through multiple stages as they discharge, forming different chemical compounds that continue to produce electricity through chemical action.

The safety factor is due to the fact that, unlike lithium-ion cells, the new batteries don’t form dendrites that short out the cell. The cells do degrade over time, but not in a way that is likely to cause a short circuit. However, ceramic coatings may provide protection against this degradation in the future which would be another benefit compared to traditional lithium batteries.

We see a lot of exciting battery announcements, but we rarely see real products with them. Time will tell if the Oxis and similar batteries based on this technology will take root.

Graphene Prints More Smoothly Under The Influence Of Alcohol

August 22, 2020 by Kristina Panos 10 Comments

If you’ve ever sloshed coffee out of your mug and watched the tiny particles scurry to the edges of the puddle, then you’ve witnessed a genuine mystery of fluid mechanics called the coffee ring effect. The same phenomenon happens with spilled wine, and with functional inks like graphene.

Graphene and other 2D crystals print much better under the influence of alcohol.

The coffee ring effect makes it difficult to print graphene and similar materials onto silicon wafers, plastics, and other hard surfaces because of this drying problem. There are already a few commercial options that can be used to combat the coffee ring effect, but they’re all polymers and surfactants that negatively affect the electronic properties of graphene.

Recently, a group of researchers discovered that alcohol is the ideal solution. In the case of spilled graphene, the particles fleeing for the edges are naturally spherical. By adding a mixture of isopropyl and 2-butanol alcohol, they get flattened into a pancake shape, resulting in smoother deformation during the drying process and an easier printing process with better results.

Graphene is quite interesting by nature, and has many uses. It can shift from an insulator to a superconductor with the right temperature changes, and it can desalinate sea water for drinking.

Printing, Plating, And Baking Makes DIY Microlattices Possible

August 19, 2020 by Dan Maloney 15 Comments

To be honest, we originally considered throwing [Zachary Tong]’s experiments with ultralight metallic microlattices into the “Fail of the Week” bucket. But after watching the video below for a second time, it’s just not fair to call this a fail, so maybe we’ll come up with a new category — “Qualified Success of the Week”, perhaps?

[Zachary]’s foray into the strange world of microlattices began when he happened upon a 2011 paper on the subject in Science. By using a special photocurable resin, the researchers were able to use light shining through a mask with fine holes to create a plastic lattice, which was then plated with nickel using the electroless process, similar to the first half of the electroless nickel immersion gold (ENIG) process used for PCBs. After removing the resin with a concentrated base solution, the resulting microlattice is strong, stiff, and incredibly light.

Lacking access to the advanced materials and methods originally used, [Zachary] did the best he could with what he had. An SLA printer with off-the-shelf resin was used to print the skeleton using the same algorithms used in the original paper. Those actually turned out pretty decent, but rather than electroless plating, he had to go with standard electroplating after a coat of graphite paint. The plated skeletons looked great — until he tried to dissolve the resin. When chemical approaches failed, into the oven went the plated prints. Sadly, it turns out that the polymers in the resin expand when heated, which blew the plating apart. A skeleton in PLA printed on an FDM printer fared little better; when heated to drive out the plastic, it became clear that the tortuous interior of the lattice didn’t plate very well.

From aerogels to graphene, we love these DIY explorations of new and exotic materials, so hats off to [Zachary] for giving it a try in the first place.

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Modified Bricks Can House Energy, Too

August 16, 2020 by Kristina Panos 43 Comments

What if building an emergency battery were as easy as painting conductive plastic onto bricks, stacking them, and charging them up? Researchers at Washington University in St. Louis have done just that — they’ve created supercapacitors by modifying regular old red bricks from various big-box hardware stores.

The bricks are coated in poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS), a conductive polymer that soaks readily into the bricks’ porous surface. When the coated brick is connected to a power source such as a solar panel, the polymer soaks up ions like a sponge. PEDOT:PSS reacts with the iron oxide in the bricks, the rust that gives them their reddish-orange color. Check out the demonstration after the break — it’s a time lapse that shows three PEDOT-coated bricks powering a white LED for ten minutes.

We envision a future where a brick house could double as a battery backup when the power goes out. The researchers thought of that too, or at least had their eye on the outdoors. They waterproofed the PEDOT-coated bricks in epoxy and found they retain 90% of their capacitance and are still efficient after 10,000 charge-discharge cycles. Since this doesn’t take any special kind of brick, it seems to us that any sufficiently porous material would work as long as iron oxide is also present for the reaction. What do you think?

If you can get your hands on the stuff, PEDOT:PSS has all kinds of uses from paper-thin conductors to homebrew organic LEDs.

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