Injection Molding IPhone Cases From Trash

February 7, 2018 by Tom Nardi 27 Comments

We imagine you’ve heard this already, but waste plastic is a problem for the environment. We wrap nearly everything we buy, eat, or drink in plastic packaging, and yet very little of it ends up getting recycled. Worse, it doesn’t take a huge industrial process to melt down a lot of this plastic and reuse it, you can do it at home if you were so inclined. So why aren’t there more localized projects to turn all this plastic trash into usable items?

That the question that [Precious Plastic] asks, and by providing a centralized resource for individuals and communities looking to get into the plastic recycling game, they hope to put a dent in the worldwide plastic crisis. One of their latest projects is showing how plastic trash can be turned into functional iPhone cases with small-scale injection molding.

The video after the break goes into intricate detail about the process involved in creating the 3D CAD files necessary to make the injection molds. Even if you don’t plan on recycling milk jugs at home, the information and tips covered in the video are extremely helpful if you’ve ever contemplated having something injection molded. The video even demonstrates a neat feature in SolidWorks that lets you simulate how molten plastic will move through your mold to help check for problem areas.

Once you’ve designed your mold on the computer, you need to turn it into a physical object. If you’ve got a CNC capable of milling aluminum then you’re all set, but if not, you’ll need to outsource it. [Precious Plastic] found somebody to mill the molds through 3DHubs, though they mention in the video that asking around at local machine shops isn’t a bad idea either.

With the mold completed, all that’s left is to bolt the two sides together and inject the liquid plastic. Here [Precious Plastic] shows off a rather interesting approach where they attach the mold to a contraption that allows them to inject plastic with human power. Probably not something you’d want to do if you’re trying to make thousands of these cases, but it does show that you don’t necessarily need a high tech production facility to make good-looking injection molded parts.

This project reminds us of the tiles made of HDPE plastic with nothing more exotic than what you’d find in the average kitchen. Projects like these really drive home the idea that with the right hardware individuals can turn trash into usable products.

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Biologic Additive May Lead To Self-Healing Concrete

January 28, 2018 by Al Williams 33 Comments

If you get a cut or break a bone, your body heals itself. This everyday miracle is what inspired [Congrui Jin] to try to find a way to make concrete self-healing. The answer she and her colleagues are working on might surprise you. They are adding fungus to concrete to enable self-repair.

It isn’t just any fungus. The conditions in concrete are very harsh, and after testing twenty different kinds, they found that one kind — trichoderma reesei — could survive inside concrete as spores. This fungus is widespread in tropical soil and doesn’t pose any threat to humans or the ecology. Mixing nutrients and spores into concrete is easy enough. When cracks form in the concrete, water and oxygen get in and the spores grow. The spores act as a catalyst for calcium carbonate crystals which fill the cracks. When the water is gone, the fungi go back to spores, ready to repair future cracking.

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An Indoor Garden? That’s Arduino-licious

January 24, 2018 by James Hobson 24 Comments

Gardening is a rewarding endeavour, and easily automated for the maker with a green thumb. With simplicity at its focus, Hackaday.io user [MEGA DAS] has whipped up a automated planter to provide the things plants crave: water, air, and light.

[MEGA DAS] is using a TE215 moisture sensor to keep an eye on how thirsty the plant may be, a DHT11 temperature and humidity sensor to check the airflow around the plant, and a BH1750FVI light sensor for its obvious purpose. To deliver on these needs, a 12V DC water pump and a small reservoir will keep things right as rain, a pair of 12V DC fans mimic a gentle breeze, and a row of white LEDs supplement natural light when required.

The custom board is an Arduino Nano platform, with an ESP01 to enable WiFi capacity and a Bluetooth module to monitor the plant’s status while at home or away. Voltage regulators, MOSFETs, resistors, capacitors, fuses — can’t be too careful — screw header connectors, and a few other assorted parts round out the circuit. The planter is made of laser cut pieces with plenty of space to mount the various components and hide away the rest. You can check out [MEGA DAS]’ tutorial video after the break!

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Shah Selbe: Science In The World’s Wildest Places

January 22, 2018 by Mike Szczys 2 Comments

When we think of building research hardware, lab coats and pristine workbenches come to mind. Shah Selbe used to do something kind of like that when he was engineering satellite propulsion systems. But after putting twelve of them into space, he ditched the office gig and took his gear to some of the wildest places on earth. He’s an explorer and fellow with the National Geographic Society, and at the Hackaday Superconference he shared his experiences building research hardware that gathers data in incredibly remote places.

Shah makes a really good point about two very different trends in our world over the past several decades. While we’ve had unparalleled technological growth, we’ve also seen horrifying wildlife trends to the point that some scientists believe we’re currently in a sixth mass extinction event. But to know that for sure, and look for ways to prevent and reverse it, we need reliable data. This is a fascinating problem because the world is huge, and we simply can’t monitor everything.

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Less Dear Heating For The Deer

January 13, 2018 by Jenny List 21 Comments

Keeping animals from tropical regions of the world in a cold climate is an expensive business, they need a warm environment in their pens and sleeping areas. Marwell Zoo was spending a small fortune keeping its herd of nyalas (an antelope, not as the title suggests a deer, native to Southern Africa) warm with electric heating, so they went looking for a technology that could reduce their costs by only heating while an animal was in its pen.

One might expect that a passive IR sensor would solve the problem, but a sleeping nyala too soon becomes part of the background heat for these devices, and as a result, the heaters would not operate for long enough to keep the animals warm. The solution came from an unlikely source, a coffee queue monitoring project at the IBM Watson headquarters in Munich, that used an array of infra-red sensors to monitor the changing heat patterns and thus gauge the likelihood of a lengthy wait for a beverage.

In the zoo application, an array of thermal sensors hooked up to ESP8266 boards talk back to a Raspberry Pi that aggregates the readings and sends them to the IBM Watson cloud where they are analyzed by a neural net. The decision is then made whether or not a nyala is in the field of view, and the animal is toasted accordingly.

This project has some similarities with a Hackaday Prize entry, automated wildlife recognition, in its use of Watson.

Nyala image: Charlesjsharp [CC BY-SA 4.0 ].

Imaging The Neighborhood With Solar Panels

January 5, 2018 by Tom Nardi 27 Comments

Like many people who have a solar power setup at home, [Jeroen Boeye] was curious to see just how much energy his panels were putting out. But unlike most people, it just so happens that he’s a data scientist with a deep passion for programming and a flair for visualizations. In his latest blog post, [Jeroen] details how his efforts to explain some anomalous data ended with the discovery that his solar array was effectively acting as an extremely low-resolution camera.

It all started when he noticed that in some months, the energy produced by his panels was not following the expected curve. Generally speaking, the energy output of stationary solar panels should follow a clear bell curve: increasing output until the sun is in the ideal position, and then decreasing output as the sun moves away. Naturally cloud cover can impact this, but cloud cover should come and go, not show up repeatedly in the data.

[Jeroen] eventually came to realize that the dips in power generation were due to two large trees in his yard. This gave him the idea of seeing if he could turn his solar panels into a rudimentary camera. In theory, if he compared the actual versus expected output of his panels at any given time, the results could be used as “pixels” in an image.

He started by creating a model of the ideal energy output of his panels throughout the year, taking into account not only obvious variables such as the changing elevation of the sun, but also energy losses through atmospheric dispersion. This model was then compared with the actual power output of his solar panels, and periods of low efficiency were plotted as darker dots to represent an obstruction. Finally, the plotted data was placed over a panoramic image taken from the perspective of the solar panels. Sure enough, the periods of low panel efficiency lined up with the trees and buildings that are in view of the panels.

We’ve seen plenty of solar hacks, but this one has to be something of a first. Usually people are more worried about maximizing efficiency or tracking the sun with them.

Fresh-Baked Plastic Tiles For All!

December 30, 2017 by James Hobson 46 Comments

Recycling aims to better the planet, but — taken into the hands of the individual — it can be a boon for one’s home by trading trash for building materials. [fokkejongerden], a student at the [Delft University of Technology] in the Netherlands, proposes one solution for all the plastic that passes through one’s dwelling by turning HDPE into tiles.

Collecting several HDPE containers — widely used and easy enough to process at home — [fokkejongerden] cleaned them thoroughly of their previous contents, and then mulched them with a food processor. An aluminium mold of the tile was then welded together making sure the sides were taller than the height of the tile. A second part was fabricated as a top piece to compress the tile into shape.

After preheating an oven to no hotter than 200 degrees Celsius, they lined the mold with parchment paper and baked the tile until shiny(90-120 minutes). The top piece was weighed down (clamping works too), compressing the tile until it cooled. A heat gun or a clothes iron did the trick to smooth out any rough edges.

Not only does [fokkejongerden]’s tiles give the recycler plenty of artistic freedom for creating their own mosaic floor, the real gem is the adaptable plastic recycling process for home use. For another method, check out this recycled, recycling factory that turns bottles in to rope and more! There’s even the potential for fueling your 3D printer.

[Via Instructables]