Try This For 3D Printing Without Support

December 29, 2017 by Al Williams 46 Comments

Have a look at the object to the right. Using a conventional fused deposition printer, how would you print the object? There’s no flat surface to lay on the bed without generating a lot of overhangs. That usually requires support.

In theory, you might be able to print the bottom of the sphere down, but it is difficult to get that little spot to adhere to the bed. If you have at least two extruders and you are set up to print support material, that might even be the best option. However, printing support out of the same material you are printing with makes it hard to get a good clean print. There is another possibility. It does require some post-processing, but then again, not as much as hacking away a bunch of support material.

A Simple Idea

The idea is simple and — at first — it will sound like a lot of trouble. The basic idea is to cut the model in half at some point where both halves would be easy to print and then glue them together. Stick around (no pun intended), though, because I’ll show you a way to make the alignment of the parts almost painless no matter how complex the object might be.

The practical problem with gluing together half models is getting the pieces in the exact position, but that turns out to be easy if you just make a few simple changes to your model. Another lesser problem is clamping a piece while gluing. You can use a vise, but some oddly-shaped parts are not conducive to traditional vise jaws.

In Practice

Starting with an OpenSCAD object, it is easy to cut the model in half. Actually, you could cut it anywhere. Then it is easy to rotate half of it so the cut line is at the bottom of each part. That doesn’t solve the alignment problem nor does it help you clamp when you glue.

The trick is to build a flange around each part. The flanges mate with a few screws after printing so alignment is perfect and bolts through the flange holes can keep the parts together and immobilized while your glue of choice sets. The kicker is that I even have an automated process to make the design side of this trick very easy.

Continue reading “Try This For 3D Printing Without Support” →

Hunting Rogue Access Points With The ESP8266

December 28, 2017 by Sean Boyce 32 Comments

Cantennas outperform every consumer-grade Wi-Fi antenna I’ve had the bad luck of purchasing. Cantenna is a mashup of ‘can’ and ‘antenna’ creating the nickname for a directional waveguide antenna built from re-purposed steel cans. For anyone who has yet to build one, it makes an excellent afternoon project. Here are some build instructions and technical details. I went beyond that, and ended up catching a rogue WiFi access point in the process.

When I needed to extend the range of some ESP8266-based sensors, cantennas were right at the top of my list of things to try. It was easy enough to build one, attach it to a Wemos Mini D1 Pro, and call the job done… leaving me with plenty of time to over-engineer it, and I ended up down a bit of a rabbit hole.

The first thing I did was stop using cans. Canned goods are not only expensive in my corner of the world, but more importantly don’t lend themselves that well to making a standardized antenna in volume. I can also only eat so many beans! The latter reason alone is enough to consider an alternative design like a modular dish reflector.

Continue reading “Hunting Rogue Access Points With The ESP8266” →

Review: IoT Data Logging Services With MQTT

October 31, 2017 by Sean Boyce 11 Comments

For the last few months, I had been using Sparkfun’s Phant server as a data logger for a small science project. Unfortunately, they’ve had some serious technical issues and have discontinued the service. Phant was good while it lasted: it was easy to use, free, and allowed me to download the data in a CSV format. It shared data with analog.io, which at the time was a good solution for data visualization.

While I could continue using Phant since it is an open-source project and Sparkfun kindly releases the source code for the server on Github, I thought it might be better to do some research, see what’s out there. I decided to write a minimal implementation for each platform as an interesting way to get a feel for each. To that end, I connected a DHT11 temperature/humidity sensor to a NodeMCU board to act as a simple data source.

Continue reading “Review: IoT Data Logging Services With MQTT” →

The Bane Of Aftermarket Car Alarms

October 10, 2017 by Zoe Skyforest 79 Comments

The humble car alarm has been around almost as long as the car itself, first being developed by an unknown prisoner in Denver, circa 1913. To the security-conscious motorist, they make a lot of sense. The noise of a car alarm draws attention which is the last thing a would-be thief wants, and the in-built immobilizers generally stop the car being moved at all without a time-consuming workaround. Both are a great deterrent to theft.

It may then surprise you to know that I, dear readers, consider the aftermarket car alarm to be one of the most heinous devices ever fitted to the modern automobile. Combining the unholy trifecta of being poorly designed, cheaply made, and fitted by only the most untalented or uncaring people to wield a soldering iron, they are a blight that I myself refuse to accept.

It was my very own Mazda that suffered at the hands of a car alarm system. Two days after purchasing the car, the keyfob died, and thus the car would no longer start. My other car was already out of action due to bent valves, and I needed to get to work, so I figured as a competent hacker, I’d be able to quickly disable it.

Continue reading “The Bane Of Aftermarket Car Alarms” →

Manufacturing Your Own Single-Origin Tea

October 2, 2017 by Sean Boyce 33 Comments

It’s nice to take a break from hacking together the newest bleeding-edge technology, relax, and enjoy a beverage. It’s no surprise that hacks devoted to beer and coffee roasting are popular. We’ve also seen a few projects helping brew the perfect cup of tea, but none involving the actual production of tea. Today we’re going to take a short recess from modernity and explore this ancient tradition.

Consumption of tea is about equal to all other manufactured beverages, such as coffee and alcohol, combined. It is hands-down the most popular manufactured beverage in the world, and we thought it would be interesting to make some ourselves. Also the local tea is so bitter that it’s used to clean things, and it works alarmingly well. To each their own!

I started by driving into Vietnam’s Central Highlands, down what Google simply refers to as ‘unnamed road’, to about 11°52’59.3″N 108°33’49.5″E. I asked around until I found a street vendor that knew a farmer at the nearby tea plantation, and would sell us five kilograms of fresh tea. I carried it 330 kilometers back to the city, because I’m a sane person that does normal things.

Continue reading “Manufacturing Your Own Single-Origin Tea” →

An Introduction To Solid State Relays

September 26, 2017 by Sean Boyce 56 Comments

When we think of relays, we tend to think of those big mechanical things that make a satisfying ‘click’ when activated. As nice as they are for relay-based computers, there are times when you don’t want to deal with noise or the unreliability of moving parts. This is where solid-state relays (SSRs) are worth considering. They switch faster, silently, without bouncing or arcing, last longer, and don’t contain a big inductor.

An SSR consists of two or three standard components packed into a module (you can even build one yourself). The first component is an optocoupler which isolates your control circuit from the mains power that you are controlling. Second, a triac, silicon controlled rectifier, or MOSFET that switches the mains power using the output from the optocoupler. Finally, there is usually (but not always) a ‘zero-crossing detection circuit’. This causes the relay to wait until the current it is controlling reaches zero before shutting off. Most SSRs will similarly wait until the mains voltage crosses zero volts before switching on.

If a mechanical relay turns on or off near the peak voltage when supplying AC, there is a sudden drop or rise in current. If you have an inductive load such as an electric motor, this can cause a large transient voltage spike when you turn off the relay, as the magnetic field surrounding the inductive load collapses. Switching a relay during a peak in the mains voltage also causes an electric arc between the relay terminals, wearing them down and contributing to the mechanical failure of the relay.

Continue reading “An Introduction To Solid State Relays” →

Linux Fu: X Command

September 21, 2017 by Al Williams 43 Comments

Text-based Linux and Unix systems are easy to manipulate. The way the Unix I/O system works you can always fake keyboard input to another program and intercept its output. The whole system is made to work that way. Graphical X11 programs are another matter, though. Is there a way to control X11 programs like you control text programs? The answer to that question depends on exactly what you want to do, but the general answer is yes.

As usual for Linux and Unix, though, there are many ways to get to that answer. If you really want fine-grained control over programs, some programs offer control via a special mechanism known as D-Bus. This allows programs to expose data and methods that other programs can use. In a perfect world your target program will use D-Bus but that is now always the case. So today we’ll look more for control of arbitrary programs.

There are several programs that can control X windows in some way or another. There’s a tool called xdo that you don’t hear much about. More common is xdotool and I’ll show you an example of that. Also, wmctrl can perform some similar functions. There’s also autokey which is a subset of the popular Windows program AutoHotKey.

Continue reading “Linux Fu: X Command” →