3D Printing In Metal: The Laser And Metal Powder Printers We Saw At IMTS

September 17, 2018 by Mike Szczys 24 Comments

Last week I went to the International Manufacturing Technology Show (IMTS) and it was incredible. This is a toy store for machinists and showcases the best of industrial automation. But one of the coolest trends I found at the show are all the techniques used to 3D print in metal. The best part is that many of the huge machines on display are actually running!

It’s probably better to refer to this as additive manufacturing, because the actual methods can be significantly different from your 3D printer. Below you’ll find examples of three different approaches to this process. I had a great interview with a company doing actual 3D printing in metal using a nozzle-based delivery often called cladding. There’s a demo video of powder layer printing using lasers. And a technique that uses binders as an intermediary step toward the final metal part. Let’s take a look!

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One Small Step For A Space Elevator

September 14, 2018 by Tom Nardi 149 Comments

Space elevators belong to that class of technology that we all want to see become a reality within our lifetimes, but deep-down doubt we’ll ever get to witness firsthand. Like cold fusion, or faster than light travel, we understand the principles that should make these concepts possible, but they’re so far beyond our technical understanding that they might as well be fantasy.

Except, maybe not. When Japan Aerospace Exploration Agency (JAXA) launches their seventh Kounotori H-II Transfer Vehicle towards the International Space Station, riding along with the experiments and supplies for the astronauts, will be a very special pair of CubeSats. They make up the world’s first practical test of space elevator technology, and with any luck, will be one of many small steps that precedes the giant leap which access to space at a fraction of the cost will be.

Of course, they won’t be testing a fully functional space elevator; even the most aggressive of timelines put us a few decades out from that. This will simply be a small scale test of some of the concepts that are central to building a space elevator, as we need to learn to crawl before we can walk. But even if we aren’t around to see the first practical space elevator make it to the top, at least we can say we were there on the ground floor.

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The DIN Rail And How It Got That Way

September 13, 2018 by Dan Maloney 56 Comments

Unless you’ve spent some time in the industrial electrical field, you might be surprised at the degree of integration involved in the various control panels needed to run factories and the like. Look inside any cabinet almost anywhere in the world, and you’ll be greeted by rows of neat plastic terminal blocks, circuit breakers, signal conditioners, and all manner of computing hardware from programmable logic controllers right on to Raspberry Pis and Arduinos.

A well-crafted industrial control panel can truly be a thing of beauty. But behind all the electrical bits in the cabinet, underneath all the neatly routed and clearly labeled wires, there’s a humble strip of metal that stitches it all together: the DIN rail. How did it come to be, and why is it so ubiquitous?

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Do Space Probes Fail Because Of Space Weather?

September 11, 2018 by Brian Benchoff 40 Comments

Over the past few decades, numerous space probes sent to the far-flung reaches of the Solar System have fallen silent. These failures weren’t due to communications problems, probes flying into scientifically implausible anomalies, or little green men snatching up the robotic scouts we’ve sent out into the Solar System. No, these space probes have failed simply because engineers on Earth can’t point them. If you lose attitude control, you lose the ability to point a transmitter at Earth. If you’re managing a space telescope, losing the ability to point a spacecraft turns a valuable piece of scientific equipment into a worthless, spinning pile of junk.

The reasons for these failures is difficult to pin down, but now a few people have an idea. Failures of the Kepler, Dawn, Hayabusa, and FUSE space probes were due to failures of the reaction wheels in the spacecraft. These failures, in turn, were caused by space weather. Specifically, coronal mass ejections from the Sun. How did this research come about, and what does it mean for future missions to deep space?

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GSM Phone Network At EMF Camp Built On Raspberry Pi And LimeSDR

August 30, 2018 by Jenny List 22 Comments

The Electromagnetic Field 2018 hacker camp in the UK will have its own GSM phone network, and as we have already covered its badge will be a fully-functional GSM phone. This is as far as we are aware a first in the world of badges, and though it may not be a first in hacker camp connectivity it is still no mean achievement at the base station side. To find out more we talked to two of the people behind the network, on the radio side Lime Microsystems‘ [Andrew Back], and on the network side Nexmo‘s developer advocate, [Sam Machin].

There are sixteen base stations spread around the site, of which each one is a Raspberry Pi 3 B+ with a LimeSDR Mini. Development of the system was undertaken prior to the release of the Raspberry Pi Foundation’s PoE board, so they take a separate 24V supply which powers the Pi through a DC-to-DC converter. This arrangement allows for a significant voltage drop should any long cable runs be required.

On the software side the base stations all run the Osmocom (Open Source Mobile Communications) cellular base station infrastructure package. It was a fine decision between the all-in-one Osmocom NITB package and the fully modular Osmocom, going for the former for its reliability. It was commented that this would not necessarily be the case at a future event but that it made sense in the present. It appears on the network as a SIP phone system, meaning that it can easily integrate with the existing DECT network. Let’s take a look at how the network operates from the user side, and the licencing loophole that makes everything possible.

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Behind The Pin: Logic Level Outputs

August 14, 2018 by Jenny List 20 Comments

There is one thing that unites almost every computer and logic circuit commonly used in the hardware hacking and experimentation arena. No matter what its age, speed, or internal configuration, electronics speak to the world through logic level I/O. A single conductor which is switched between voltage levels to denote a logic 1 or logic zero. This is an interface standard that has survived the decades from the earliest integrated circuit logic output of the 1960s to the latest microcontroller GPIO in 2018.

The effect of this tried and true arrangement is that we can take a 7400 series I/O port on an 8-bit microcomputer from the 1970s and know with absolute confidence that it will interface without too much drama to a modern single-board computer GPIO. When you think about it, this is rather amazing.

It’s tempting to think then that all logic level outputs are the same, right? And of course they are from a certain viewpoint. Sure, you may need to account for level shifting between for example 5V and 3.3V families but otherwise just plug, and go, right? Of course, the real answer isn’t quite that simple. There are subtle electrical differences between the properties of I/O lines of different logic and microcontroller families. In most cases these will never be a problem at all, but can rear their heads as edge cases which the would-be experimenter needs to know something about.

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The VU Meter And How It Got That Way

August 9, 2018 by Dan Maloney 44 Comments

Given its appearance in one form or another in all but the cheapest audio gear produced in the last 70 years or so, you’d be forgiven for thinking that the ubiquitous VU meter is just one of those electronic add-ons that’s more a result of marketing than engineering. After all, the seemingly arbitrary scale and the vague “volume units” label makes it seem like something a manufacturer would slap on a device just to make it look good. And while that no doubt happens, it turns out that the concept of a VU meter and its execution has some serious engineering behind that belies the really simple question it seeks to answer: How loud is this audio signal?

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