3D Printing The Final Frontier

December 18, 2017 by Tom Nardi 29 Comments

While down here there’s room for debate about the suitability of 3D printing for anything more serious than rapid prototyping, few would say the same once you’ve slipped the surly bonds of Earth. With 3D printing, astronauts would have the ability to produce objects and tools on-demand from a supply of inert raw building materials. Instead of trying to pack every conceivable spare part for a mission to Mars, replacements (assuming a little forward thinking on the part of the spacecraft designers) can be made to order out of the stock of raw plastic or metal kept on-board. The implications of such technology for deep space travel or off-world settlement simply cannot be overstated.

In the more immediate future, 3D printing can be used to rapidly develop and deploy unmanned spacecraft. Tiny satellites (referred to as CubeSats) could be printed, assembled, and deployed by astronauts already in orbit. Innovations such as these could allow science missions to be planned and executed in months instead of years, and at a vastly reduced cost.

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Thermistors And 3D Printing

December 15, 2017 by Al Williams 24 Comments

I always find it interesting that 3D printers — at least the kind most of us have — are mostly open-loop devices. You tell the head to move four millimeters in the X direction and you assume that the stepper motors will make it so. Because of the mechanics, you can calculate that four millimeters is so many steps and direct the motor to take them. If something prevents that amount of travel you get a failed print. But there is one part of the printer that is part of a closed loop. It is very tiny, very important, but you don’t hear a whole lot about it. The thermistor.

The hot end and the heated bed will both have a temperature sensor that the firmware uses to keep temperatures at least in the ballpark. Depending on the controller it might just do on-and-off “bang-bang” control or it might do something as sophisticated as PID control. But either way, you set the desired temperature and the controller uses feedback from the thermistor to try to keep it there.

If you print with high-temperature materials you might have a thermocouple in your hot end, but most machines use a thermistor. These are usually good to about 300 °C. What got me thinking about this was the installation of an E3D V6 clone hot end into my oldest printer which had a five-year-old hot end in it. I had accumulated a variety of clone parts and had no idea what kind of thermistor was in the heat block I was using.

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Hardware Heroes: Isambard Kingdom Brunel

December 15, 2017 by Jenny List 45 Comments

There are some notable figures in history that you know of for just one single thing. They may have achieved much in their lifetimes or they may have only been famous for Andy Warhol’s fifteen minutes, but through the lens of time we only know them for that single achievement. Then on the other hand there are those historic figures for whom there is such a choice of their achievements that have stood the test of time, that it is difficult to characterize them by a single one.

[Isambard Kingdom Brunel], in front of the launching chains for the Great Eastern. [Public domain] — Isambard Kingdom Brunel, in front of the launching chains for the *Great Eastern*. [Public domain]

Such is the case of Isambard Kingdom Brunel, the subject of today’s Hardware Heroes piece. Do we remember him for his involvement in the first successful tunnel to pass beneath a river, as a builder of some of the most impressive bridges on the 19th century, the innovator in all aspects of rail engineering, the man behind the first screw-driven ocean-going iron ship, or do we remember him as all of those and more?

It is possible that if you are not British, or in particular you are not from the West of England, this is the first you’ve heard of Brunel. In which case he is best described as a towering figure of many aspects of engineering over the middle years of the 19th century. His influence extended from civil engineering through the then-emerging rail industry, to shipbuilding and more, and his legacy lives on today in that many of his works are still with us.

Engineering: The Family Trade

Brunel’s father, Marc Brunel, was an engineer and refugee from the French Revolution who found success in providing the British Navy with a mass-production system for wooden pulley blocks as used in the rigging of sailing ships. He enters this story for his grand project, the world’s first tunnel to be dug under a navigable river, beneath London’s River Thames from Rotherhithe to Wapping, and for his patented tunneling shield which made it possible to be dug.

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Using Gmail With OAUTH2 In Linux And On An ESP8266

December 14, 2017 by Sean Boyce 21 Comments

One of the tasks I dread is configuring a web server to send email correctly via Gmail. The simplest way of sending emails is SMTP, and there are a number of scripts out there that provide a simple method to send mail that way with a minimum of configuration. There’s even PHP mail(), although it’s less than reliable.

Out of the box, Gmail requires OAUTH2 for authentication and to share user data, which has the major advantage of not requiring that you store your username and password in the application that requires access to your account. While they have an ‘allow less secure apps’ option that allows SMTP access for legacy products like Microsoft Outlook, it just doesn’t seem like the right way forward. Google documents how to interact with their API with OAUTH2, so why not just use that instead of putting my username and password in plaintext in a bunch of prototypes and test scripts?

Those are the thoughts that run through my head every time this comes up for a project, and each time I’ve somehow forgotten the steps to do it, also forgotten to write it down, and end up wasting quite a bit of time due to my own foolishness. As penance, I’ve decided to document the process and share it with all of you, and then also make it work on an ESP8266 board running the Arduino development environment.

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Truly Terrible Dimensioned Drawings

December 14, 2017 by Brian Benchoff 147 Comments

I’m in the planning stages of a side project for Hackaday right now. It’s nothing too impressive, but this is a project that will involve a lot of electromechanical parts. This project is going to need a lot of panel mount 1/8″ jacks and sockets, vertical mount DIN 5 connectors, pots, switches, and other carefully crafted bits of metal. Mouser and Digikey are great for nearly every other type of electrical component, but when it comes to these sorts of electromechanical components, your best move is usually to look at AliExpress or DealExtreme, finding something close to what you need, and buying a few hundred. Is this the best move for a manufacturable product? No, but we’re only building a few hundred of these things.

I have been browsing my usual Internet haunts in the search for the right bits of stamped brass and injection molded plastic for this project, and have come to a remarkable conclusion. Engineers, apparently, have no idea how to dimension drawings. Drafting has been a core competency for engineers from the dawn of time until AutoCAD was invented, and now we’re finally reaping the reward: It’s now rare to find a usable dimensioned drawing on the Internet.

This post is going to be half rant, half explanation of what is wrong with a few of the dimensioned drawings I’ve found recently. Consider this an example of what not to do. There is no reason for the state of engineering drawing to be this bad.

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Accident Forgiveness Comes To GPLv2

December 13, 2017 by Tom Nardi 40 Comments

Years ago, while the GPLv3 was still being drafted, I got a chance to attend a presentation by Richard Stallman. He did his whole routine as St IGNUcius, and then at the end said he would be answering questions in a separate room off to the side. While the more causal nerds shuffled out of the presentation room, I went along with a small group of free software aficionados that followed our patron saint into the inner sanctum.

When my turn came to address the free software maestro, I asked what advantages the GPLv3 would have to a lowly hacker like myself? I was familiar with the clause about “Tivoization“, the idea that any device running GPLv3 code from the manufacturer should allow the user to be able to install their own software on it, but this didn’t seem like the kind of thing most individuals would ever need to worry about. Was there something in the new version of the GPL that would make it worth adopting in personal or hobby projects?

Interestingly, a few years after this a GPLv2 program of mine was picked up by a manufacturer and included in one of their products (never underestimate yourself, folks). So the Tivoization clause was actually something that did apply to me in the end, but that’s not the point of this story.

Mr. Stallman responded that he believed the biggest improvement GPLv3 made over v2 for the hobbyist programmer was the idea of “forgiveness” in terms of licensing compliance. Rather than take a hard line approach like the existing version of the GPL, the new version would have grace periods for license compliance. In this way, legitimate mistakes or misunderstandings of the requirements of the GPL could be resolved more easily.

So when I read the recent announcement from Red Hat that said they would be honoring the grace period for GPLv2 projects, I was immediately interested. Will the rest of the community follow Red Hat’s lead? Will this change anyone’s mind when deciding between the GPL v2 and v3? Is this even a good idea? Join me below as I walk through these questions.

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Christal Gordon: Sensors, Fusion, And Neurobiology

December 12, 2017 by Al Williams 3 Comments

Some things don’t sound like they should go together, but they do. Peanut butter and chocolate. Twinkies and deep frying. Bacon and maple syrup. Sometimes mixing things up can produce great results. [Dr. Christal Gordon’s] expertise falls into that category. She’s an electrical engineer, but she also studies neuroscience. This can lead to some interesting intellectual Reese’s peanut butter cups.

At the 2017 Hackaday Superconference, [Christal] spoke about sensor fusion. If you’ve done systems that have multiple sensors, you’ve probably run into that before even if you didn’t call it that. However, [Christal] brings the perspective of how biological systems fuse sensor data contrasted to how electronic systems perform similar tasks. You can see a video replay of her talk in the video below.

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