Retrotechtacular: Automatic For The People

Throughout their long history, American Machine and Foundry (AMF) have made forays into many areas of automation. And as the American cultural landscape of the 1950s and ’60s shifted toward fast, cheap, and convenient foodstuffs available for consumption inside of spacious, finned automobiles, AMF was there with AMFare, an (almost) completely automated system for taking orders, preparing food, and calculating bills.

AMF named the system “ORBIS” after its two main functions, ordering and billing. But ORBIS was not completely autonomous. A human operator received orders from a table-side telephones inside the restaurant and intercoms used by drive-in customers, and entered them on an enormous console. Orders were routed to several machines to prepare the food, cook it, and package it in various ways. We witness the odyssey of the burger in complete detail, from punching out perfect patties to their final, plastic-wrapped form.

Surprisingly, the AMFare selection wasn’t limited to delicious burgers, fries, and milkshakes. It could crank out sixteen different menu items, and do so pretty quickly. In the space of one hour, AMFare could produce more than 400 burgers, over 350 orders of fries, or about 700 milkshakes. Even so, collating the orders required human intervention. We imagine that the awful task of cleaning all that expensive Rube Goldberg-esque machinery did, too.

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We Have A Problem: 3D Printers Are Too Expensive

Hackaday, we have a problem. 3D printing is changing the world but it’s still too expensive to be embraced as a truly transformative technology.

With each passing year, the 3D printing industry grows by leaps and bounds. Food safe PLA is now the norm, with dissolvable and other exotic filaments becoming more mainstream.  New filaments are making it possible to print objects that were not possible before. New CAD software is popping up like dandelions, with each iteration giving novice users a friendly and more intuitive interface to design 3D models. As time marches on, and we look into its future, a vision of the 3D printing world is evident – its only going to get bigger.

3d printerImagine a future where a 3D printer is as common as an ink jet printer in homes all across the world.  A future where you could buy filament from the supermarket down the street, and pick up a new printer from any hardware store. A future where dishwashers, refrigerators and bicycles come with .stl files that allow you to print upgrades or spare parts. A future where companies compete to give the market easy-to-use printers at the cheapest price.

Is this future possible? Not until the technology changes. It’s too expensive, and that’s the problem you’re going to solve. How can you make a 3D printer cheaper? A cheap printer could change the game and make our future a reality.

Where do we need cost savings?

To get you going, here are some parts of common 3D Printers which think need to find cost-saving solutions.

XYZ AND HOT END MOTORS

Stepper motors are going to run you about $15 each. Is it possible to use cheaper DC motors with some type of position tracking while keeping the cost down?

HARDWARE

Threaded rod is probably the cheapest way to move your XYZ axis. What about couplings and guide rods? Check out how this guy made a CNC out of parts from his local hardware store.

ELECTRONICS

No arduino with Easysteppers here – too expensive. We’ve just seen a super cheap controller a few days ago. If we use something other than NEMA steppers, it will radically change the typical electronic controller for our super cheap 3d printer.

EXTRUDER

What is the cheapest way to melt and extrude plastic? What about using thermistors in place of thermocouples? Let’s think out of the box with this, and see if we can get away from the typical stepper motor based extruder. Remember, everything is low cost. If we have to sacrifice some resolution, that is OK.

So there you go. Let’s hear your input on the issue. We need to make 3D printers a lot more affordable and we want to hear any ideas you have on the topic in the comments below. Do you think this is in our future and why?


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Hackaday Links: June 7, 2015

I’ve said over and over again that Apple’s MagSafe port is the greatest advancement in laptop tech in the last 15 years. Those charger connectors break, though, so how do you fix it? With Lego, of course (Google translatrix). Use a light-colored 1×4 brick so the LED will shine through.

Want to learn Git commands? Here’s a great game that does just that. It’s a really well-designed game/tutorial that walks you through basic Git commands.

Lets say you’re just slightly paranoid about the Bad Guys™ getting into your computer with 0-days and roller blades. You’d like to connect this computer to the Internet, but you don’t want to leave it connected all the time. The solution? A timer for an Ethernet switch. It’s actually a better solution than doing the same thing with scripts: there’s a real, physical interface, and if the Bad Guys™ get in when you are connected, they could just enable the network adapter anyway. An extremely niche use case, but that’s 99% of the security hacks we see.

The DaVinci 3D printer is an okay printer if you’re cool with the Gilette model. The filament cartridges are chipped, and the software is proprietary. These problems have been solved, and now you can use a standard RepRap heated bed and glass with the DaVinci. At this point, people are buying the DaVinci just to tear it apart.

Crowdfunding Follies: Debunking The Batteriser

It’s not on Kickstarter yet, but this product is already making its media debut, with features in all the tech blogs, an astonishing amount of print outlets, and spouted from the gaping maws of easily impressed rubes the world over. What is it? It’s the Batteriser, a tiny metal contraption that clips over AA, C, and D cells that reclaims the power trapped inside every dead battery. Yes, every dead battery you’ve ever thrown away still has up to 80% of its power remaining. Sounds like complete hogwash, right? That’s because it is.

[Dave Jones] put together a great video on the how comes and why nots of the Batteriser, and while doing so gives a great tutorial for debunking a product, heavily inspired by [Carl Sagan]’s Baloney Detection Kit. The real  debunking starts by verifying any assumptions, and the biggest fault of the Batteriser campaign is claiming 80% of a battery’s power is unused. Lucky for us, [Dave] has tons of tools and graphs to demonstrate this is not the case.

To verify the assumption that battery-powered devices will brown out after using only 20% of a battery’s available power, [Dave] does the most logical thing and looks at the data sheets for a battery. After using 20% of available power, these datasheets claim these batteries should be around 1.3V. Do devices brown out at 1.3V? Hook it up to a programmable power supply and find out.

It turns out every battery-powered device [Dave] could find worked perfectly until around 1.1V. Yes, that’s only 0.3V difference from 1.4V claimed by the patent for the Batteriser, but because of the battery discharge curve, that means 80% of the power in a normal device is already being used up. The premise of the Batteriser is invalid, and [Dave] demonstrates it’s a complete scam.

If a through debunking of the Batteriser’s claims wasn’t enough, [Dave] goes on to explain how it may actually be dangerous. The positive terminal of a battery is also the metal can, while the negative terminal is just a tiny nib of metal seperated from the rest of the battery by a gasket. Since the Batteriser is made of metal and serves as the ground for the boost converter circuit, it’s very, very close to shorting through the branding and logo emblazoned on a mylar wrapping each battery is shrouded with. One tiny nick in this insulator, and you have a direct short across the battery. That’s going to turn to heat, and there’s a lot of energy in a D cell; a failure mode for the Batteriser is a fire. That’s just terrible product design.

Video below.

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Hacklet 50 – Hydroponic Projects

Growing plants without soil has been has been amazing people for centuries. First written about in the 1600’s, hydroponics has become an industry with numerous techniques for germinating and sustaining both plant and animal life. It comes as no surprise then that hackers, makers, engineers, and scientists have been working with and improving hydroponic systems for centuries. Hydroponic plant growth is a project you can really sink your teeth into, as there’s nothing sweeter than eating the fruits and vegetables of your labor. This week’s Hacklet is all about the best hydroponic projects on Hackaday.io!

hydropwnWe start with HydroPWNics, [Adam Vadala-Roth’s] entry in The 2015 Hackaday Prize. [Adam] is creating a universal system with will work with both hydroponic and soil based grow systems. The hydroponic setup will consist of plants in a PVC gutter system. Water will be pumped to the top gutter, and flow down via gravity through the plant roots and back to the reservoir. The system will be monitored and controlled by a DyIO controller. Props to [mad.hephaestus] for creating DyIO, a project seeing reuse in the Hackaday.io community!

 

hydro2Next up is [Justin] with AAGriculture, an Automated Aquaponic Garden. AAGriculture is aquaponic system, which means it uses a symbiotic relationship between plants and fish to make more food for humans to eat. The fish in this case are bluegill and bullhead. A Raspberry Pi controls the system, while A Teensy-LC is used to help out with some of the real-time duties, like monitoring a PH probe. [Justin] is even using CO2 tanks to keep dissolved gasses in check. He must be doing something right, as his tomatoes are now over 23″ tall!

 

homer[Em] brings us 5g Aquaponics. 5g aquaponics isn’t a next generation cellular system, nor a 5.8 GHz WiFi setup, it’s an aquaponic system in a 5 Gallon bucket. Anyone from the US  will recognize the orange “Homer Bucket” from Home Depot. 5g Aquaponics includes a window, allowing the underwater workings to be monitored. Speaking of monitoring, 5g aquaponics is a manual affair – [Em] hasn’t used any electronics here. The idea is to create a system that is easy to get up and running for those who are new to Hydro/Aquaponic setups. [Em] is using a dual zone root system. The plant grows in dirt within a burlap fabric. The fabric then sits in a water bath which also houses the fish. Air pumped through an airstone keeps everything circulating. [Em’s] initial version of the project worked a bit too well. The tomato plant grew so large that the roots strangled the fish! Hopefully both flora and fauna are happy with this new rev 2.0!

 

smartAquaFinally we have [Kijani grows] with Smart Aquaponics, which was [Kijani’s] entry in The 2014 Hackaday Prize. One wouldn’t expect fish, plants and Linux to mix, but that is exactly what is going on here. Linux runs on the popular Wr703n router, while a custom ATmega328 Arduino compatible board keeps track of the sensors.  The second version of the system will run on an ATmega2560 and an AR9331 module, all housed on one board. The system does work, and it’s been expanded from a single fish tank to a large flood/drain table complete with grow lights, all kept at [Kijani’s] office. The biggest problems [Kijani] has run into are little things like misplaced resistors masquerading as kernel bugs.

Still haven’t eaten your veggies? Want to see more hydroponic projects? Check out our new hydroponic projects list! That’s it for this week’s Hacklet, As always, see you next week. Same hack time, same hack channel, bringing you the best of Hackaday.io!

Embed With Elliot: Multiplexing SPI Uses Few Pins

[Ralph Doncaster], aka Nerdralph, seems to be absolutely driven to see how few resources he can use on a microcontroller to get the job done. In this post on his blog, [Ralph] writes some custom bit-banged SPI code to cut the number of SPI lines necessary to drive an nRF24L01+ radio module from four down to two. That really helps if you’re using a micro with only six free pins, like an ATtiny85.

If you’re going to say, “why don’t you just buy a bigger microcontroller?”, you’re missing the point. This exercise strikes us as optimization for optimization’s sake and a dirty hack, both of which are points in its favor.  There are also a couple of techniques here for your mental toolbox. We thought it was interesting enough to look at in depth.

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Weekly Winners: Stickvise

We’re in the middle of an epic run to award $50,000 in loot to Hackaday Prize entries this summer. This week we doled out a Stickvise low-profile PCB vise to 65 different projects! This actually started out as a really great project on Hackaday.io.

Winners are listed below, please check out their projects; skull the ones you find awesome and leave your words of encouragement as comments on those projects. Then get to work and submit something of your own. Your odds of winning during these weekly giveaways are quite good. Our recommendation for your best chances at winning are to polish up the information you’re sharing — tell the whole story of what you’ve done so far and what you plan to do. Post some images whether pictures of the prototype, renders of what you are working on, or hand-drawn diagrams from the back of a napkin.

Normally we launch the following week’s contest in this winner-announcement post. But we’re changing it up a bit this time around. Look for a post on Monday that shares all the details of what is coming next!

Last Week’s Winners of 65 Stickvise

Each project creator will find info on redeeming their prize as a message on Hackaday.io.


The 2015 Hackaday Prize is sponsored by: