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.

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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.

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34C3: The First Day Is A Doozy

December 27, 2017 by Elliot Williams 8 Comments

It’s 5 pm, the sun is slowly setting on the Leipzig conference center, and although we’re only halfway through the first day, there’s a ton that you should see. We’ll report some more on the culture of the con later — for now here’s just the hacks. Continue reading “34C3: The First Day Is A Doozy” →

2017: As The Hardware World Turns

December 27, 2017 by Brian Benchoff 28 Comments

The year is almost over, and now it’s time to look back on the last fifty-odd weeks. What happened in this year in hacking? 2017 will go down as the beginning of another AI renaissance, although we’re not going to call it that; this year was all about neural nets and machine learning and advancements resulting from the development of self-driving cars and very beefy GPUs. Not since the 80s have we seen more work in ‘AI’ fields. What will it amount to this time around the hype cycle? Find out in a few years.

Biohacking was big this year, and not just because people are installing RFID tags and magnets in their hands. CRISPR is allowing for Star Trek-style genome hacking, and this year saw in vivo experiments to enable and disable individual genes in rat models. Eventually, someone is going to get a Nobel for CRISPR.

We’re going to Mars, and soon — very soon — a SpaceX Falcon Heavy is going to either lob a Tesla Roadster into solar orbit or the Atlantic Ocean. We learned about the BFR that will take dozens of people to Mars in a single launch. Boeing and Lockheed think they can compete with the Elon Musk PR powerhouse. The Bigelow Aerospace inflatable module passed its in-flight test on the ISS, giving the space station a new storage closet. Even in space, amazing stuff is happening this year.

Is that it? Not by a long shot. This year has seen some of the coolest hacks we’ve ever seen, and some of the dumbest security breaches ever. Hackaday is doing awesome. What else did 2017 have? Read on to find out.

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Fast 3D Printing With Raspberry Pi — But Not How You Think

December 26, 2017 by Al Williams 117 Comments

Although we tend to think of 3D printers as high-tech toys, most of them are not especially powerful in the brain department. There are some exceptions, but most 3D printers run on either an 8-bit Arduino or some Arduino variant with a lot of I/O. There are a few 32-bit boards, but if you grab a random 3D printer, its brain is going to be an 8-bit AVR running something like Marlin or Repetier. It isn’t uncommon to see a Raspberry Pi connected to a printer, too, but — again, in general — it is a network interface that handles sending G-code to the 8-bit controller that runs the stepper motors. Would it make more sense to do things like parse G-code, map out curves, and set accelerations in the relatively powerful Raspberry Pi and relegate the 8-bit AVR to just commanding motors and heaters? [KevinOConnor] thinks so, and he wrote Klipper to prove it.

Klipper is mostly written in Python and it does most of the functions of traditional 3D printing firmware. It communicates with the onboard microprocessor by providing a schedule of when to do what tasks. The microprocessor then handles the timing and things like motion control for the axes and extruder. Klipper can control multiple microprocessors with no trouble and keeps them in synchronization, so you could have a processor for your extruder and one for each stepper, for example. You can use Klipper with a Cartesian machine, a delta, or a Core XY-style printer.

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Coin Cells: The Mythical Milliamp-Hour

December 22, 2017 by Elliot Williams 16 Comments

Just how much metaphorical juice is in a coin cell battery? It turns out that this seemingly simple question is impossible to answer — at least without a lot of additional information. The problem is that the total usable energy in a battery depends on how you try to get that energy out, and that is especially true of coin cells.

For instance, ask any manufacturer of the common 3 V lithium 2032 batteries, and they’ll tell you that it’s got 230 mAh. That figure is essentially constant across brands and across individual cells, and if you pull a constant 0.2 mA from the battery, at room temperature and pressure, you’ll get a bit more than the expected 1,150 hours before it dips below the arbitrary voltage threshold of 2.0 V. Just as it says on the tin.

What if you want to do anything else with a coin cell? Run an LED for a decade? Pull all the energy out right now and attempt to start a car? We had these sorts of extreme antics in mind when we created the Coin Cell Challenge, but even if you just want to do something mundane like run a low-power radio sensor node for more than a day, you’re going to need to learn something about the way coin cells behave in the real world. And to do that, you’re going to need to get beyond the milliamp hour rating. Let’s see how deep this rabbit hole goes.

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Magic Leap Finally Announced; Remains Mysterious

December 21, 2017 by Mike Szczys 74 Comments

Yesterday Magic Leap announced that it will ship developer edition hardware in 2018. The company is best known for raising a lot of money. That’s only partially a joke, since the teased hardware has remained very mysterious and never been revealed, yet they have managed to raise nearly $2 billion through four rounds of funding (three of them raising more than $500 million each).

The announcement launched Magic Leap One — subtitled the Creator Edition — with a mailing list sign up for “designers, developers and creatives”. The gist is that the first round of hardware will be offered for sale to people who will write applications and create uses for the Magic Leap One.

We’ve gathered some info about the hardware, but we’ll certainly begin the guessing game on the specifics below. The one mystery that has been solved is how this technology is delivered: as a pair of goggles attaching to a dedicated processing unit. How does it stack up to current offerings?

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