Engineering

573 Articles

Hacking When It Counts: DIY Prosthetics And The Prison Camp Lathe

July 14, 2025 by 9 Comments

There are a lot of benefits to writing for Hackaday, but hands down one of the best is getting paid to fall down fascinating rabbit holes. These often — but not always — delightful journeys generally start with chance comments by readers, conversations with fellow writers, or just the random largesse of The Algorithm. Once steered in the right direction, a few mouse clicks are all it takes for the properly prepared mind to lose a few hours chasing down an interesting tale.

I’d like to say that’s exactly how this article came to be, but to be honest, I have no idea where I first heard about the prison camp lathe. I only know that I had a link to a PDF of an article written in 1949, and that was enough to get me going. It was probably a thread I shouldn’t have tugged on, but I’m glad I did because it unraveled into a story not only of mechanical engineering chops winning the day under difficult circumstances, but also of how ingenuity and determination can come together to make the unbearable a little less trying, and how social engineering is an important a skill if you want to survive the unsurvivable.

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Field Guide To The North American Weigh Station

June 26, 2025 by 39 Comments

A lot of people complain that driving across the United States is boring. Having done the coast-to-coast trip seven times now, I can’t agree. Sure, the stretches through the Corn Belt get a little monotonous, but for someone like me who wants to know how everything works, even endless agriculture is fascinating; I love me some center-pivot irrigation.

One thing that has always attracted my attention while on these long road trips is the weigh stations that pop up along the way, particularly when you transition from one state to another. Maybe it’s just getting a chance to look at something other than wheat, but weigh stations are interesting in their own right because of everything that’s going on in these massive roadside plazas. Gone are the days of a simple pull-off with a mechanical scale that was closed far more often than it was open. Today’s weigh stations are critical infrastructure installations that are bristling with sensors to provide a multi-modal insight into the state of the trucks — and drivers — plying our increasingly crowded highways.

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Mining And Refining: Drilling And Blasting

June 24, 2025 by 21 Comments

It’s an inconvenient fact that most of Earth’s largesse of useful minerals is locked up in, under, and around a lot of rock. Our little world condensed out of the remnants of stars whose death throes cooked up almost every element in the periodic table, and in the intervening billions of years, those elements have sorted themselves out into deposits that range from the easily accessed, lying-about-on-the-ground types to those buried deep in the crust, or worse yet, those that are distributed so sparsely within a mineral matrix that it takes harvesting megatonnes of material to find just a few kilos of the stuff.

Whatever the substance of our desires, and no matter how it is associated with the rocks and minerals below our feet, almost every mining and refining effort starts with wresting vast quantities of rock from the Earth’s crust. And the easiest, cheapest, and fastest way to do that most often involves blasting. In a very real way, explosives make the world work, for without them, the minerals we need to do almost anything would be prohibitively expensive to produce, if it were possible at all. And understanding the chemistry, physics, and engineering behind blasting operations is key to understanding almost everything about Mining and Refining.

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Reconductoring: Building Tomorrow’s Grid Today

June 11, 2025 by 65 Comments

What happens when you build the largest machine in the world, but it’s still not big enough? That’s the situation the North American transmission system, the grid that connects power plants to substations and the distribution system, and which by some measures is the largest machine ever constructed, finds itself in right now. After more than a century of build-out, the towers and wires that stitch together a continent-sized grid aren’t up to the task they were designed for, and that’s a huge problem for a society with a seemingly insatiable need for more electricity.

There are plenty of reasons for this burgeoning demand, including the rapid growth of data centers to support AI and other cloud services and the move to wind and solar energy as the push to decarbonize the grid proceeds. The former introduces massive new loads to the grid with millions of hungry little GPUs, while the latter increases the supply side, as wind and solar plants are often located out of reach of existing transmission lines. Add in the anticipated expansion of the manufacturing base as industry seeks to re-home factories, and the scale of the potential problem only grows.

The bottom line to all this is that the grid needs to grow to support all this growth, and while there is often no other solution than building new transmission lines, that’s not always feasible. Even when it is, the process can take decades. What’s needed is a quick win, a way to increase the capacity of the existing infrastructure without having to build new lines from the ground up. That’s exactly what reconductoring promises, and the way it gets there presents some interesting engineering challenges and opportunities.

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Is The Atomic Outboard An Idea Whose Time Has Come?

June 10, 2025 by 48 Comments

Everyone these days wants to talk about Small Modular Reactors (SMRs) when it comes to nuclear power. The industry seems to have pinned its hopes for a ‘nuclear renaissance’ on the exciting new concept. Exciting as it may be, it is not exactly new: small reactors date back to the heyday of the atomic era. There were a few prototypes, and a lot more paper projects that are easy to sneer at today. One in particular caught our eye, in a write-up from Steve Wientz, that is described as an atomic outboard motor.

It started as an outgrowth from General Electric’s 1950s work on airborne nuclear reactors. GE’s proposal just screams “1950s” — a refractory, air-cooled reactor serving as the heat source for a large turboprop engine. Yes, complete with open-loop cooling. Those obviously didn’t fly (pun intended, as always) but to try and recoup some of their investment GE proposed a slew of applications for this small, reactor-driven gas turbine. Rather than continue to push the idea of connecting it to a turboprop and spew potentially-radioactive exhaust directly into the atmosphere, GE proposed podding up the reactor with a closed-cycle gas turbine into one small, hermetically sealed-module. Continue reading “Is The Atomic Outboard An Idea Whose Time Has Come?” →

Information Density: Microfilm And Microfiche

June 9, 2025 by 18 Comments

Today, we think nothing of sticking thousands of pages of documents on a tiny SD card, or just pushing it out to some cloud service. But for decades, this wasn’t possible. Yet companies still generated huge piles of paper. What could be done? The short answer is: microfilm.

However, the long answer is quite a bit more complicated. Microfilm is, technically, a common case of the more generic microform. A microform is a photographically reduced document on film. A bunch of pages on a reel of film is microfilm. If it is on a flat card — usually the size of an index card — that’s microfiche. On top of that, there were a few other incidental formats. Aperture cards were computer punch cards with a bit of microfilm included. Microcards were like microfiche, but printed on cardboard instead of film.

In its heyday, people used specialized cameras, some made to read fanfold computer printer paper, to create microfilm. There were also computer output devices that could create microfilm directly.

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The Potential Big Boom In Every Dust Cloud

June 2, 2025 by 49 Comments

To the average person, walking into a flour- or sawmill and seeing dust swirling around is unlikely to evoke much of a response, but those in the know are quite likely to bolt for the nearest exit at this harrowing sight. For as harmless as a fine cloud of flour, sawdust or even coffee creamer may appear, each of these have the potential for a massive conflagration and even an earth-shattering detonation.

As for the ‘why’, the answer can be found in for example the working principle behind an internal combustion engine. While a puddle of gasoline is definitely flammable, the only thing that actually burns is the evaporated gaseous form above the liquid, ergo it’s a relatively slow process; in order to make petrol combust, it needs to be mixed in the right air-fuel ratio. If this mixture is then exposed to a spark, the fuel will nearly instantly burn, causing a detonation due to the sudden release of energy.

Similarly, flour, sawdust, and many other substances in powder form will burn gradually if a certain transition interface is maintained. A bucket of sawdust burns slowly, but if you create a sawdust cloud, it might just blow up the room.

This raises the questions of how to recognize this danger and what to do about it.

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