It’s Time For Direct Metal 3D-Printing

May 19, 2016 by Moritz Walter 75 Comments

It’s tough times for 3D-printing. Stratasys got burned on Makerbot, trustful backers got burned on the Peachy Printer meltdown, I burned my finger on a brand new hotend just yesterday, and that’s only the more recent events. In recent years more than a few startups embarked on the challenge of developing a piece of 3D printing technology that would make a difference. More colors, more materials, more reliable, bigger, faster, cheaper, easier to use. There was even a metal 3D printing startup, MatterFab, which pulled off a functional prototype of a low-cost metal-powder-laser-melting 3D printer, securing $13M in funding, and disappearing silently, poof.

This is just the children’s corner of the mall, and the grown-ups have really just begun pulling out their titanium credit cards. General Electric is on track to introduce 3D printed, FAA-approved fuel nozzles into its aircraft jet engines, Airbus is heading for 3D-printed, lightweight components and interior, and SpaceX has already sent rockets with 3D printed Main Oxidizer Valves (MOV) into orbit, aiming to make the SuperDraco the first fully 3D printed rocket engine. Direct metal 3D printing is transitioning from the experimental research phase to production, and it’s interesting to see how and why large industries, well, disrupt themselves.

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To See Within: Making Medical X-rays

May 12, 2016 by Dan Maloney 47 Comments

I was a bit of a lost soul after high school. I dabbled with electrical engineering for a semester but decided that it wasn’t for me – what I wouldn’t give for a do-over on that one. In my search for a way to make money, I stumbled upon radiologic technology – learning how to take X-rays. I figured it was a good way to combine my interests in medicine, electronics, and photography, so after a two-year course of study I got my Associates Degree, passed my boards, and earned the right to put “R.T.(R) (ARRT)” after my name.

That was about as far as that career went. There are certain realities of being in the health care business, and chief among them is that you really have to like dealing with the patients. I found that I liked the technology much more than the people, so I quickly moved on to bigger and better things. But the love of the technology never went away, so I thought I’d take a look at exactly what it takes to produce medical X-rays, and see how it’s changed from my time in the Radiology Department.

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Don’t Ignore The Artist’s Supply Store

May 10, 2016 by Gerrit Coetzee 49 Comments

So it’s Saturday morning and you’ve found yourself with an urge to build something involving copper plates or carbon electrodes. Maybe you need a metallic powder for a chemistry experiment. Casting supplies? Pure lead? Copper mesh? Silver wire? Odd tools? Exceedingly caustic etchants? There’s a store that sells it all, and it’s not usually frequented by hackers: the art store.

If you know where to look, the store is full of useful things. Each method of expression in art has its own set of supplies; a bountiful collection of various processes and the useful things therein. I grew up in a city that did not have a real art supply store. It had one of those big box craft stores that assault you with glittery plasticized flowers and terrible manufactured scents. When I moved to a different city and walked over to the local art supply to purchase some new pens I ended up staying for a few hours just looking at all the cool things they had for sale.

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The Coming Wide-Spread Use Of Drones In Agriculture

May 9, 2016 by Donald Papp 39 Comments

Whether you call them UAVs (Unmanned Aerial Vehicles), UAS (Unmanned Aerial System), Drones, or something less polite – people are more familiar than ever with them. We’ll call them drones, and we’re not talking about the remote-controlled toy kind – we’re talking about the flying robot kind. They have sensors (GPS and more), can be given a Flight Plan (instructions on where to go), and can follow that plan autonomously while carrying out other instructions – no human pilot required. Many high-end tractors are already in service with this kind of automation and we’ve even seen automated harvesting assistance. But flying drones are small and they don’t plant seeds or pull weeds, so what exactly do they have to do with agriculture?

There are certain things that drones are very good at, and there are things in agriculture that are important but troublesome to do or get. Some of these things overlap, and in those spaces is where a budding industry has arisen.

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Evolving Our Ideas To Build Something That Matters

April 27, 2016 by Moritz Walter 45 Comments

When Jeffrey Brian “JB” Straubel built his first electric car in 2000, a modified 1984 Porsche 944, powered by two beefy DC motors, he did it mostly for fun and out of his own curiosity for power electronics. At that time, “EV” was already a hype among tinkerers and makers, but Straubel certainly pushed the concept to the limit. He designed his own charger, motor controller, and cooling system, capable of an estimated 288 kW (368 hp) peak power output. 20 lead-acid batteries were connected in series to power the 240 V drive train. With a 30-40 mile range the build was not only road capable but also set a world record for EV drag racing.

jb-straubel-porsche — The “Electric Porsche 944” – by JB Straubel

The project was never meant to change the world, but with Tesla Motors, which Straubel co-founded only a few years later, the old Porsche 944 may have mattered way more than originally intended. The explosive growth between 2000 and 2010 in the laptop computer market has brought forth performance and affordable energy storage technology and made it available to other applications, such as traction batteries. However, why did energy storage have to take the detour through a bazillion laptop computers until it arrived at electro mobility?

You certainly won’t find that grail of engineering by just trying hard. Rather than feverishly hunting down the next big thing or that fix for the world’s big problems, we sometimes need to remind ourselves that even a small improvement, a new approach or just a fun build may be just the right ‘next step’. We may eventually build all the things and solve all the problems, but looking at the past, we tend to not do so by force. We are much better at evolving our ideas continuously over time. And each step on the way still matters. Let’s dig a bit deeper into this concept and see where it takes us.

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Can You Hear Me Now?

September 30, 2015 by Rud Merriam 29 Comments

It’s great to build projects just to do something neat, to learn; to impress friends and other hackers. It’s even better to address a real need.

I’ve worn hearing aids for 40 some years. My response to the question “Can you hear me now?” is still all too often, “No.” Because of this I heartily applaud the Aegis Acoustics Headset currently active on Kickstarter. I’m happy to see it’s blown through its goal with over a month left.

The Aegis is targeted at prevent hearing loss, primarily in teens since they use headsets so often. It’s equally applicable to adults and pre-teens. The Aegis works by limiting the sound level emitted to 85db, which is a safe level. Above that the risk of damage to the tiny hairs in the cochlea – the inner ear – increases dramatically with a 3db increase cutting the safety time in half.

Future’s So Bright I’ve Got to Wear ‘Aids

My personal experience explains why this is important. At my first professional level job as a software developer I noticed that people at the other end of the table often mumbled during meetings. Not really, because everyone else understood them fine. I needed hearing aids.

My first hearing aids were analog devices. There were three frequency bands across the audio spectrum whose volumes could be custom set for my ears — resulting in crude and limited improvements in what I could hear. My current hearing aids are technological marvels of digital signal processing with a multitude of algorithms the audiologist can use to help me hear better. They even coordinate their actions by communicating between themselves.

I still need to ask people to repeat what they say at times. But who doesn’t? I had a successful career despite my loss. But it is still a royal pain-in-the-butt to miss out on one-third of the dialog in a movie, to not go to a local coffee house because I won’t understand the lyrics or comments by the musicians, and miss out on all the other small parts of life along these lines.

Hacking for Hearing

There are a range of areas where hackers could contribute and not just in assisting individuals, like myself, who personally gain from technological assistance.

Consider how the cell phone improved communications in developing countries. Using radio communications the countries avoided the need to string thousands of miles of wires. That saved the expense and the decades of construction time. It’s easier to get cell phone service than water in some locations. It’s important to notice that it didn’t come about because of a big plan. It came about as an unseen consequence of a technical development.

“We can rebuild him…we have the technology” is from the opening of an old TV series and movies, “The 6 Million Dollar Man” and has found it’s place in the pop-culture vocabulary. But it rings true. We have the technology. We have the tools. We have the expertise. We’re hackers and builders. We and the technology are all over the place. We’re a solution looking for a problem.

Devices that Extend the Body

All signs point to a coming revolution of devices that protect our bodies and make them work better. The 2015 Hackaday Prize theme is Build Something That Matters and that sentiment is obviously taking hold throughout the hardware hacker movement. The Aegis headphones I mentioned above are one example of preventive devices, but look around and there are many more like the UV-Badge which gives you feedback on safe levels of sunlight for your skin.

Surely we’re going to see further augmentation for the devices that help restore function. Wearables are all the rage, how long will it be before your smartwatch notification functions make it into my hearing aids? Imagine the improvements we will see in custom hearing profiles born of that smartphone-hearing aid connection. The foundations of this are user-controlled profile switching which is already in place for apps like Belltone’s HearPlus. If the advanced electronics in the smartphone can build a better noise profile and transfer it to the hearing aid my visits to the coffee shop just might get a lot better. And this doesn’t mean the devices need to look the same either. I love the Design Affairs Studio hearing aid concept that is shown at the top of this article. Hardware can be a status symbol after all.

This type of forward thinking easily extends to all assistive technologies such as wheelchair improvements and navigation systems for the blind.

As you look toward your next big hack, roll these concepts around in your mind. The tools, software, and talent have never been easier to connect for our group of citizen scientists who are hacking in basements and garages. It’s exciting to think about the change we can affect using the skills honed over the past decades of this hardware enlightenment we’re all living.

3D Printing Has Evolved Two Filament Standards

September 29, 2015 by Brian Benchoff 56 Comments

We’re far beyond the heyday of the RepRap project, and the Hackaday tip line isn’t seeing multiple Kickstarters for 3D printers every week. In a way, this is a bit of a loss. The rapid evolution of the low-cost 3D printer seen in the first half of this decade will never be matched, and from now on we’ll only see incremental improvements instead of the revolutionary steps taken by the first Prusa, the first Printrbot, and even the Makerbot Replicator.

This doesn’t mean everything is standardized. There’s still enough room for arguing over deltas versus Cartesians, beds moving on the Y axis versus moving along the Z, and a host of other details that make the current crop of printers so diverse. One of these small arguments is especially interesting: the diameter of the filament. Today, you can get any type of plastic you want, in any color, in two sizes: 1.75 and 3mm. If you think about it, it’s bizarre. Why on Earth would filament manufacturers, hot end fabricators, and even printer manufacturers decide to support two different varieties of the same consumable? The answer is a mix of a historical choice, engineering tradeoffs, and an absolutely arbitrary consequence of what 3D printers actually do.

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