Relativity Space’s Quest To 3D Print Entire Rockets

October 30, 2018 by Tom Nardi 27 Comments

While the jury is still out on 3D printing for the consumer market, there’s little question that it’s becoming a major part of next generation manufacturing. While we often think of 3D printing as a way to create highly customized one-off objects, that’s a conclusion largely based on how we as individuals use the technology. When you’re building something as complex as a rocket engine, the true advantage of 3D printing is the ability to not only rapidly iterate your design, but to produce objects with internal geometries that would be difficult if not impossible to create with traditional tooling.

So it’s no wonder that key “New Space” players like SpaceX and Blue Origin make use of 3D printed components in their vehicles. Even NASA has been dipping their proverbial toe in the additive manufacturing waters, testing printed parts for the Space Launch System’s RS-25 engine. It would be safe to say that from this point forward, most of our exploits off of the planet’s surface will involve additive manufacturing in some capacity.

But one of the latest players to enter the commercial spaceflight industry, Relativity Space, thinks we can take the concept even farther. Not content to just 3D print rocket components, founders Tim Ellis and Jordan Noone believe the entire rocket can be printed. Minus electrical components and a few parts which operate in extremely high stress environments such as inside the pump turbines, Relativity Space claims up to 95% of their rocket could eventually be produced with additive manufacturing.

If you think 3D printing a rocket sounds implausible, you aren’t alone. It’s a bold claim, so far the aerospace industry has only managed to print relatively small rocket engines; so printing an entire vehicle would be an exceptionally large leap in capability. But with talent pulled from major aerospace players, a recently inked deal for a 20 year lease on a test site at NASA’s Stennis Space Center, and access to the world’s largest metal 3D printer, they’re certainly going all in on the idea. Let’s take a look at what they’ve got planned.

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New Part Day: ST’s New 3D Printer Motor Driver

October 29, 2018 by Brian Benchoff 21 Comments

ST has released a new evaluation board for a stepper motor driver. It’ll plug right into your 3D printer, and if you’re looking for a chip to build a cheap 3D printer controller board around, this might be the one.

We’ve come a long way in the field of stepper motor drivers in just a few short years. The first popular driver for RepRap electronics was ‘the Pololu’, a stepper motor carrier board using Allegro’s A4988 driver. If you had a big heat sink, this driver could deliver 2 A per coil, operated between 8 and 35 V, and had microstep resolution down to 1/16th. Was it the best stepper driver around? No, but it was cheap, it was everywhere, and RAMPS, the popular RepRap control electronics picked up on its pinout and accidentally created a standard. The DRV8825 motor driver from TI followed next, with microstepping down to 1/32nd, a little more current per coil, and arguably a better thermal design.

Then the wave of Trinamic drivers happened. The Trinamic TMC2100 was a silent stepper motor driver when running a motor at medium or low speeds. With this driver, you could run a motor more efficiently, which means the motor doesn’t get as hot. There are diagnostics via SPI. Tom liked it, and now in every Prusa i3, you’ll find a bunch of Trinamic drivers.

ST’s new offering, the STSPIN820, doesn’t have the fancy-schmancy features the Trinamic driver does, but the chip itself is fantastically cheap, at about 1/5th the price of a Trinamic driver. As far as feature set, you should probably look at this new chip as an upgrade to the A4988, with much higher microstepping and slightly higher current handling.

If you’d like to experiment with the evaluation module, you can grab one from an ST distributor; at the time of this writing, there were seventeen of these modules available worldwide. If you’d just like to play with the STSPIN820 motor driver chip, ten thousand are available between Mouser and Digikey, starting at $2.97 in quantity one. If someone could tell electronics manufacturers to build more than a dozen evaluation boards at a time, that would be great.

Supercon Badge Hardware Hacking: Here’s What To Bring

October 25, 2018 by Roger Cheng 29 Comments

Hackaday Superconference is just a week away (precious few tickets remain), a celebration of all things Hackaday, which naturally includes creative projects making the most of their hardware. Every attendee gets a platform for hacking in the form of the conference badge.

To make the most of your badge hacking fun, plan ahead so you will have the extra components and the tools you need. At the most basic, bring along a serial to USB cable and a PIC programmer. These are common and if you don’t own them, ask around and you will likely be able to borrow them. Now is also the time to put in a parts order for any components you want to use but don’t have on hand!

The badge is hackable without any extras, but it’s designed for adding hardware and hacking the firmware. We’re excited to see what you can do with it. We gave an overview of this retro themed pocket computer a few days ago, today we’re inviting you to exploit its potential for your hardware hacks.

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Putting A Motor Inside A Speed Controller

October 23, 2018 by Brian Benchoff 17 Comments

One of the more interesting hacks we’ve seen this year is [Carl]’s experimentations with making motors out of PCBs. Honestly, it’s surprising no one has done this before — a brushless motor is just some coils of wire and a few magnets; anyone can turn some coils into traces and make a 3D print that will hold a few magnets. This latest advancement is something else entirely. It’s a motor and an electronic speed controller all in one.

This project is a continuation of [Carl]’s PCB motor project, which started with him routing coils for a brushless motor as traces in a circuit board. Previously, we’ve seen [Carl]’s motor spinning on its own with the help of a small hobby ESC / motor controller meant for model planes and drones. This time, we’ve got something different. It’s an entire controller and motor, integrated into one single PCB.

This is a very, very small motor and ESC combo. The motor driver is a 3x3mm QFN package, and most of the other components are 0201. The main parts are a very tiny triple half-bridge motor driver and a PIC16F microcontroller. This PIC reads a hall sensor to detect the speed of the motor, and with just three pins — power, ground, and a PWM pin — this motor can spin at a set speed.

The future goals of this project are to make it work just like any other hobby ESC — just plug it into a servo controller and let ‘er rip. Since this motor with an integrated PCB requires only three connections, we’re looking at a great tool to add motion and rotation to any project. It’s fantastic, and we can’t wait to see something like this in robots, toys, and other home goods.

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Bradley Gawthrop Loves Wiring And So Should You

October 19, 2018 by Tom Nardi 12 Comments

Wiring is one of those things that we’ve all had to do on a project, but probably didn’t give a lot of thought to. It’s often the last thing that happens during the build, and almost certainly doesn’t get approached with any kind of foresight. You look at the components you need to connect, dig through the parts bins until you find something that looks like it should fit, and tack it in with a blob of solder and perhaps some hot glue if you’re feeling really fancy. We’re all guilty of it from time to time, but Bradley Gawthrop is here to tell you there’s a better way.

If you’re hoping his talk from the 2017 Hackaday Superconference contains “One crazy trick” for turning your normal rat’s nest of wiring into a harness worthy of the Space Shuttle, sorry to disappoint. Bradley acknowledges it takes some extra planning and a couple specialized tools, but the end results speak for themselves. While his talk is a must-watch for anyone looking to master the arcane arts of electron corralling, his post-talk chat with Elliot Williams after the break is a great primer for the how and why of everyone’s least favorite part of building their own hardware.

Bradley will be at Supercon again this year. It’s one anecdote for the concentration of awesome people you find at the event. We’re now just two seeks away so go get your ticket and then join us after the break for the interview.

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New Part Day: The RISC-V Chip With Built-In Neural Networks

October 8, 2018 by Brian Benchoff 87 Comments

After exploring a few random online shops one day, [David] (thanks for sending this in, by the way) ran across a very interesting chip. It’s a dual-core, RISC-V chip running at 400MHz. There’s 6 MB of SRAM on the CPU, and there’s 2MB for convolutional neural network acceleration. There is, apparently, WiFi on some versions. There are already SDKs available on GitHub, and a bare chip costs a dollar or two. Interested? Log in to Taobao, realize Taobao does pre-orders, and all this can be yours.

This is a preorder — because apparently you can do that as a seller on TaoBao, but the Sipeed M1 K210 is available as a ‘core’ board with 72 pins in a one-inch square package, a version with WiFi, or as a complete development board with an OV2640 camera, 2.4 inch LCD, microphone, and onboard USB. There are videos of this chip running a face detection routine. It found Obama.

A bit of googling tells us this chip comes from a company named Kendryte, and here the specs are repeated: this is a dual-core RISC-V with an FPU, a bunch of RAM, and can run TensorFlow. Documentation is available, although the datasheet will need to be translated, and as of this writing there’s a GitHub filled with SDKs and examples, with some of the repos updated in the last hour.

Over the years we’ve seen a few RISC-V chips given development boards, and you can buy them right now. The HiFive 1 is an exceptionally powerful microcontroller with processing power that puts it right up against the Teensy (which is built around a Freescale chip), but it’s also fairly expensive. We’re not sure the Arduino Cinque (also RISC-V) ever made it to production, but again, expensive. The idea that a RISC-V microcontroller could be available for just a few dollars is very interesting, it even comes with SDKs and utilities to make the chip useful.

The Carbon Fiber Construction Of Large Propellers

October 6, 2018 by Brian Benchoff 11 Comments

Props for your little RC airplane or drone are effectively consumables. They’re made of plastic, they’re cheap, and you’re going to break a lot of them. When you start swinging something larger than 12 inches or so, things start getting expensive. If you’re building gigantic octocopters or big RC planes, those props start adding up. You might not think you can build your own gigantic carbon fiber propellers, but [Tech Ingredients] is here to prove you wrong with an incredible video demonstration of the construction of large propellers

The key ideas behind the build are laid out in a video demonstration for building a single prop. The base begins with a CNC wire cut foam air foil. This foam airfoil is first modified for the attachment point by cutting a plug out of the root of the airfoil which is filled with epoxy.

With the skeleton of the airfoil complete, the build then moves on to laminating the foam core with carbon fiber. The epoxy itself is West Systems Pro-Set laminating epoxy, although we suspect the ubiquitous West Systems epoxy used for all those live-edge ‘river’ coffee tables will also work as well. This epoxy is spread out on a table, the carbon fiber laid over it, and a second layer of carbon fiber (check ‘yo biases!) laid over that. This is wrapped around the foam core, then cured with an electric heating pad.

Of course, this is only a demonstration of making a single blade for a prop. The next trick is turning that single blade into a propeller. This is done with a cleverly machined hub, attached through that epoxy plug placed in the foam core. The results are just as good as any large prop you could buy, and this has the added benefit of being something you made, not bought.

This is really a master class in composite construction, and well worth an hour’s of YouTube viewing. You can check out the intro video below.

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