E3D Teaches Additive 3D-Printers How To Subtract

August 18, 2020 by Sonya Vasquez 29 Comments

We might’ve thought that extrusion based 3D printers have hit their peak in performance capabilities. With the remaining process variables being tricky to model and control, there’s only so much we can expect on dimensional accuracy from extruded plastic processes. But what if we mixed machines, adding a second machining process to give the resulting part a machined quality finish? That’s exactly what the folks at E3D have been cooking up over the last few years: a toolchanging workflow that mixes milling and 3D printing into the same process to produce buttery smooth part finishes with tighter dimensional accuracy over merely 3D printing alone.

Dubbed ASMBL (Additive/Subtractive Machining By Layer), the process is actually the merging of two complimentary processes combined into one workflow to produce a single part. Here, vanilla 3D printing does the work of producing the part’s overall shape. But at the end of every layer, an endmill enters the workspace and trims down the imperfections of the perimeter with a light finishing pass while local suction pulls away the debris. This concept of mixing og coarse and fine manufacturing processes to produce parts quickly is a re-imagining of a tried-and-true industrial process called near-net-shape manufacturing. However, unlike the industrial process, which happens across separate machines on a large manufacturing facility, E3D’s ASMBL takes place in a single machine that can change tools automatically. The result is that you can kick off a process and then wander back a few hours (and a few hundred tool changes) later to a finished part with machined tolerances.

What are the benefits of such an odd complimentary concoction, you might ask? Well, for one, truly sharp outer corners, something that’s been evading 3D printer enthusiasts for years, are now possible. Layer lines on vertical surfaces all but disappear, and the dimensional tolerances of holes increases as the accuracy of the process is more tightly controlled (or cleaned up!) yielding parts that are more dimensionally accurate… in theory.

But there are certainly more avenues to explore with this mixed process setup, and that’s where you come in. ASMBL is still early in development, but E3D has taken generous steps to let you build on top of their work by posting their Fusion 360 CAM plugin, the bill-of-materials and model files for their milling tool, and even the STEP files for their toolchanging motion system online. Pushing for a future where 3d printers produce the finer details might just be a matter of participating.

It’s exciting to see the community of 3D printer designers continue to rethink the capabilities of its own infrastructure when folks start pushing the bounds beyond pushing plastic. From homebrew headchanging solutions that open opportunity by lowering the price point, to optical calibration software that makes machines smarter, to breakaway Sharpie-assisted support material, there’s no shortage of new ideas to play with in an ecosystem of mixed tools and processes.

Have a look at ASMBL at 2:29 in their preview after the break.

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The Mostly Forgotten Story Of Atmospheric Railway

August 17, 2020 by Jenny List 58 Comments

It doesn’t matter whether you know it as a railway, a railroad, a chemin de fer, or a 铁路, it’s a fair certainty that the trains near where you live are most likely to be powered either by diesel or electric locomotives. Over the years from the first horse-drawn tramways to the present day there haven’t been many other ways to power a train, and since steam locomotives are largely the preserve of museums in the 21st century, those two remain as the only two games in town.

But step back to the dawn of the railway age, and it was an entirely different matter. Think of those early-19th-century railway engineer-barons as the Elon Musks and Jeff Bezos’ of their day, and instead of space and hyperloop startups their playground was rail transport. Just as some wild and crazy ideas are spoken about in the world of tech startups today, so it was with the early railways. One of the best-known of these even made it to some real railways, I’m speaking of course about the atmospheric railway.

These trains were propelled not by a locomotive, but by air pressure pushing against a piston in a partially evacuated tube between the tracks.

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Open And Sustainable Engineering Hack Chat

August 17, 2020 by Dan Maloney No comments

Join us on Wednesday, August 19 at noon Pacific for the Open and Sustainable Engineering Hack Chat with Joshua Pearce!

Since the first of our hominid ancestors learned to pick up a rock and make it into a tool, we humans have been using our engineering skills to change the world. For most of the 2 million or so years since that first technological leap, natural materials like stone and wood were the focus of our engineering projects, and except for a few tantalizing remnants, most of what was built has returned to the Earth whence it came.

Then we discovered other materials; we learned to free metals from rocks and how to harvest the fossilized hydrocarbon remains of ancient plants. Iron, aluminum, plastic, and silicon became our stock in trade, and the planet is now layered so thick with these materials and the byproducts of harvesting them that a new geological epoch, the Anthropocene Epoch, has been proposed to cover this time of human activity and its impact on the geological record.

But if we humans are clever enough to make such an impact, we should be clever enough to think our way out of the mess, and wise enough to see the need. That’s where the efforts of Dr. Pearce’s research at the Michigan Tech Open Sustainability Technology (MOST) lab are focused. Dr. Pearce envisions a sustainable future powered by pervasive solar photovoltaic systems and using open-source technologies like 3D printing to drive new models for manufacturing. We’ve recently seen interesting work from his lab, like this grinder that makes custom compression screws for plastic recycling. The MOST page on Hackaday.io is filled with other great examples of the technology that supports their mission, from low-cost environmental testing instruments to 3D-printable microfluidics.

Dr. Pearce will join us on the Hack Chat to talk about open and sustainable engineering. Be sure to stop by with your questions and to find out what you can do to engineer a brighter future, starting right in your own shop.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, August 19 at 12:00 PM Pacific time. If time zones baffle you as much as us, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.

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Hackaday Links: August 16, 2020

August 16, 2020 by Dan Maloney 16 Comments

Potentially bad news for those of us who prefer not to be assimilated into the Google hive mind: Mozilla seems to be on the rocks. Citing revenue problems, the maker of Firefox and other popular tools will be trimming 250 employees, about a quarter of its workforce, and shuttering its office in Taipei. CEO Mitchell Baker specifically mentioned that “development tools, internal tooling, and platform feature development” in the Firefox team would see reduced investment. Like a lot of companies do these days, she managed to blame COVID-19 for the company’s woes. That seems a little specious to us, but whatever the reason for the downturn in revenue, here’s hoping that Mozilla can keep Firefox alive.

Speaking of our evil overlords, looks like it another one of those “oopsies” moment for Google when it “accidentally” activated some of its smart speakers to listen into household events without the wake word. In this case, a user reported getting a text about a smoke alarm going off in their home. The alarm was not a surprise, since the user was cooking at the time, but the notification was, since they didn’t opt into that particular service. Google’s response was that an update pushed to the speaker accidentally activated that feature, a situation that they say has since been rectified. To be clear, this is an interesting feature and one of the more compelling use cases we’ve seen for a smart speaker, but it’s something we’d certainly want to sign off on before it’s activated. Yes, accidents happen, but these kinds of accidents seem to happen to Google an awful lot lately.

We’ve probably all had the experience over the last few months of being in public when the urge to cough hits. Masked or not, you struggle to fight back the tickle, lest someone hear you and think you’re infected. But now it’s possible for a computer to cough-shame you, thanks to a deep learning cough locater. The model was trained against recordings of people coughing and is coupled to an acoustic camera, which identifies the cougher with a bounding box and a contour image of the cough which looks for all the world like a virtual cloud of microbes. It’s genuinely interesting technology, sort of the public health version of ShotSpotter, but we doubt it’ll be of much practical use in public; if you want to find someone who has just coughed, someone acting like this will likely already be on the case.

Modern jet fighter technology is advancing rapidly, so much so that the forces they can apply during extreme maneuvers can quickly be lethal to pilots. Given that humans aren’t likely to evolve the ability to resist turning into a puddle of goo under high g-forces anytime soon, fighters of the future will likely incorporate AI of some sort. To prepare for that eventuality, the Defense Advanced Research Projects Agency (DARPA) is running some AI fighter competitions this week that really look interesting. Dubbed Alpha Dogfight Trials, the challenge starts with simulated dogfights between AI systems. The winner of those rounds will go up against a human pilot in the final match, which will be streamed live with commentary and multi-screen coverage. You need to register to get in on the action, and time is limited.

And finally, let these three words roll around in your head for a minute: robotic chameleon tongue. It’s actually nowhere near as disturbing as it sounds, since at its heart the “Snatcher” is actually just a beefed-up tape measure. Designed for remote retrieval tasks, the Snatcher can shoots it steel proboscis out almost a meter in just 600 milliseconds. Its designers envision uses for it on drones, but we can see it potentially being deployed on satellites too. It shouldn’t be too hard to build something like this at home, either.

Hammer Seeks Nail

August 15, 2020 by Elliot Williams 22 Comments

People sometimes say “when you have a hammer, everything looks like a nail” as if that were a bad thing. Hitting up Wikipedia, they’re calling it the Law of the Instrument or Maslow’s Hammer and calling it a cognitive bias. But I like hammers…

I’m working on a new tool, a four-axis hot-wire foam cutter based roughly on this design, but built out of stuff in my basement so far. I want it primarily to turn out wings for RC airplanes so that I can play around with airfoils and construction methods and so on. But halfway through building this new “hammer”, I’m already getting funny ideas of other projects that could be built with it. Classic nail-seeking behavior.

And some of these thoughts are making me reconsider the design of my hammer. I originally wanted to build it low, because it’s not likely that I’ll ever want to cut wing sections taller than 50 mm or so. But as soon as cutting out giant letters to decorate my son’s room, or maybe parts for a boat hull enter my mind, that means a significantly taller cutter, with ensuing complications.

So here I am suffering simultaneously from Maslow’s Hammer and scope creep, but I’m not sad about either of these “ills”. Playing with a couple manual prototypes for the CNC hot-wire cutter has expanded my design vocabulary; I’ve thought of a couple cool projects that I simply wouldn’t have had the mental map for before. Having tools expands the possible ways you can build, cognitive bias or not.

One person’s scope creep is another’s “fully realizing the potential of a project”. I’m pretty sure that I’ll build a version two of this machine anyway, so maybe it’s not a big deal if the first draft were height-limited, but the process of thinking through the height problem has actually lead me to a better design even for the short cutter. (Tension provided by an external bow instead of born by the vertical CNC towers. I’ll write the project up when I’m done. But that’s not the point.)

Maybe instead of lamenting Maslow’s cognitive bias, we should be celebrating the other side of the same coin: that nails are tremendously useful, and that the simple fact of having a hammer can lead you to fully appreciate them, and in turn expand what you’re capable of. As for scope creep? As long as I get the project done over my vacation next week, all’s well, right?

How To Choose The Right GPS Module For Your Project

August 14, 2020 by Lewin Day 26 Comments

You’ve built a brand new project, and it’s a wonderful little thing that’s out and about in the world. The only problem is, you need to know its location to a decent degree of accuracy. Thankfully, GPS is a thing! With an off-the-shelf module, it’s possible to get all the location data you could possibly need. But how do you go about it, and what parts are the right ones for your application? For the answers to these questions, read on! Continue reading “How To Choose The Right GPS Module For Your Project” →

Hackaday Podcast 080: Trucks On A Wire, Seeing Sounds, Flightless Drone, And TEA Laser Strike

August 14, 2020 by Mike Szczys 1 Comment

Hackaday editors Elliot Williams and Mike Szczys flip through the index of great hacks. This week we learn of a co-existence attack on WiFi and Bluetooth radios called Spectra. The craftsmanship in a pneumatic drone is so awesome we don’t care that it doesn’t fly. Building a powerful TEA laser is partly a lesson in capacitor design. And join us in geeking out at the prospect of big rigs getting their juice from miles of overhead wires.

Take a look at the links below if you want to follow along, and as always, tell us what you think about this episode in the comments!

Direct download (60 MB or so.)