Vernier Calipers And Micrometer Screw Gauges, Measuring Without Compromise

June 8, 2020 by Jenny List 62 Comments

I needed a temperature controller module recently, so off I went to Banggood to order one. As one does I found myself browsing, one thing led to another, and I bought a micrometer screw gauge. While micrometers are pretty expensive devices, reflecting their high precision engineering and construction, this micrometer cost me only about £8, or just under $10, definitely in the spirit of our long-running series of reviewing very cheap tools in search of a diamond in the rough. But perhaps more importantly, this is also the cue for an examination of high precision dimensional measurement. So I’ve assembled a collection of micrometers and vernier calipers of varying quality, and it’s time to dive in and measure some very small things.

Some of you will be metrology enthusiasts with an array of the finest devices available, but I am guessing that many of you will not. The ubiquitous precision measurement device in our community appears to be the digital caliper, a sliding clamp with an LCD display, an instrument that can be had in its most basic form for a very small outlay indeed. For the purposes of this piece though we’re not looking at digital devices but their analogue precursors. If you want a feel for metrology and you’d like some of those heritage tools that parents pass onto their kids then it’s time to learn something about the vernier caliper and the micrometer. Continue reading “Vernier Calipers And Micrometer Screw Gauges, Measuring Without Compromise” →

3D Printing Nuclear Reactors For Fun And Profit

June 8, 2020 by Maya Posch 18 Comments

Over the past decades, additive manufacturing (AM, also known as 3D printing) has become increasingly common in manufacturing processes. While immensely helpful in the prototyping of new products by allowing for rapid turn-around times between design and testing, these days additive manufacturing is used more and more often in the production of everything from small production runs of custom enclosures to hard to machine components for rocket engines.

The obvious advantage of additive manufacturing is that they use generic equipment and common materials as input, without requiring expensive molds as in the case of injection molding, or extensive, wasteful machining of raw materials on a lathe, mill, and similar equipment. All of the manufacturing gets reduced to a 3D model as input, one or more input materials, and the actual device that converts the 3D model into a physical component with very limited waste.

In the nuclear power industry, these benefits haven’t gone unnoticed, which has led to 3D printed parts being developed for everything from keeping existing plants running to streamlining spent fuel reprocessing and even the printing of entire nuclear reactors.

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Ancient History Of The Phone Jack

June 5, 2020 by Al Williams 67 Comments

While watching a video about old radios from the 1920s, a phone jack popped up. The host mentioned that phone jacks are super old and he wondered what was their origin. I always assumed they had something to do with the telephone system, and that’s right, but I had no idea how old they really are and how they’ve evolved. Turns out the venerable plug goes back to at least 1878.

Keep in mind, I’m talking about the good old fashioned 1/4″ phone jack with two wires. Over time, the jack and plug have spawned different versions with more wires and — particularly — smaller dimensions. The headphone jack that many smartphone makers are dropping is a direct descendant of that old phone jack. But a mono cable like you would see connecting an electric guitar or another mono source would be right at home connected to a 1900s switchboard. Let’s take a look at the origins of a design that’s almost 150 years old and still in use.

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Netbooks: The Form Factor Time Forgot

June 4, 2020 by Zoe Skyforest 172 Comments

Long ago, before smartphones were ubiquitous and children in restaurants were quieted with awful games on iPads, there was a beautiful moment. A moment in which the end user could purchase, at a bargain price, an x86 computer in a compact, portable shell. In 2007, the netbook was born, and took the world by storm – only to suddenly vanish a few years later. What exactly was it that made netbooks so great, and where did they go?

A Beautiful Combination

An Asus EEE PC shown here running Linux. You could run anything on them! Because they were real, full-fat computers. No locked down chipsets or BIOS. Just good, clean, x86 fun.

The first machine to kick off the craze was the Asus EEE PC 701, inspired by the One Laptop Per Child project. Packing a 700Mhz Celeron processor, a small 7″ LCD screen, and a 4 GB SSD, it was available with Linux or Windows XP installed from the factory. With this model, Asus seemed to find a market that Toshiba never quite hit with their Libretto machines a decade earlier. The advent of the wireless network and an ever-more exciting Internet suddenly made a tiny, toteable laptop attractive, whereas previously it would have just been a painful machine to do work on. The name “netbook” was no accident, highlighting the popular use case — a lightweight, portable machine that’s perfect for web browsing and casual tasks.

But the netbook was more than the sum of its parts. Battery life was in excess of 3 hours, and the CPU was a full-fat x86 processor. This wasn’t a machine that required users to run special cut-down software or compromise on usage. Anything you could run on an average, low-spec PC, you could run on this, too. USB and VGA out were available, along with WiFi, so presentations were easy and getting files on and off was a cinch. It bears remembering, too, that back in the Windows XP days, it was easy to share files across a network without clicking through 7 different permissions tabs and typing in your password 19 times.

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Surviving The Pandemic As A Hacker: Peering Behind The Mask

June 3, 2020 by Jenny List 30 Comments

We’re now several months into the global response to the COVID-19 pandemic, with most parts of the world falling somewhere on the lockdown/social distancing/opening up path.

It’s fair to say now that while the medical emergency has not passed, the level of knowledge about it has changed significantly. When communities were fighting to slow the initial spead, the focus was on solving the problem of medical protection gear and other equipment shortages at all costs with some interesting yet possibly hazardous solutions. Now the focus has moved towards protecting the general public when they do need to venture out, and as society learns to get life moving again with safety measures in place.

So, we all need masks of some sort. What type to do you need? Is one type better than another? And how do we all get them when everyone suddenly needs what was once a somewhat niche item?

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Ford’s Powershift Debacle

June 3, 2020 by Zoe Skyforest 203 Comments

In the automotive world, change is a constant, and if you’re not keeping up, you’re falling behind. New technologies and methodologies are key to gaining an edge in the market, and companies invest billions each year trying to find the next big thing, or even the next minor incremental improvement.

In just such a quest, Ford Motor Company decided to explore an alternative to the traditional automatic gearbox, aiming for greater fuel efficiency in their small cars. On paper, there were gains to be had. Unfortunately, not everything went according to plan. Continue reading “Ford’s Powershift Debacle” →

Inputs Of Interest: ErgoDox Post-Mortem

June 2, 2020 by Kristina Panos 18 Comments

In the last installment, I told you I was building an open-source, split, ortholinear keyboard called the ErgoDox. I’m doing this because although I totally love my Kinesis Advantage, it has made me want to crack my knuckles and explore the world of split keyboards. Apparently there are several of you who want to do the same, as evidenced by your interest in the I’m Building an ErgoDox! project on IO. Thank you!

Well boys and girls, the dust has settled, the soldering iron has cooled, and the keycaps are in place. The ErgoDox is built and working. Now that it’s all said and done, let me tell you how it went. Spoiler alert: not great. But I got through it, and it keyboards just like it’s supposed to. I’m gonna lay this journey out as it happened, step by step, so you can live vicariously through my experience.