How To Try Generative Optimization At Home

March 29, 2020 by Donald Papp 29 Comments

Chairs, spokes on a wheel, bridges, and all kinds of other load-bearing objects are designed such that material is only present where it is needed. There’s a process by which the decisions about how much material to put and where is determined by computer, and illustrating this is [Adam Bender]’s short primer on how to use generative optimization in Autodesk’s Fusion 360 (which offers a variety of free licenses) using a wheel as an example.

Things start with a solid object and a definition of the structural loads expected. The computer then simulates the force (or forces) involved, and that simulation can be used to define a part that only has material where it’s really needed. The results can be oddly organic looking, and this process has been used to optimize spacebound equipment where every gram counts.

It’s far from an automated process, but it doesn’t look too difficult to navigate the tools for straightforward designs. [Adam] cautions that one should always be mindful of the method of manufacturing when designing the part’s final form, which is always good advice but especially true when making oddball shapes and curves. To see the short process in action, watch the video embedded below.

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Can Solder Paste Stencils Be 3D Printed? They Can!

March 27, 2020 by Donald Papp 37 Comments

3D printed solder paste stencil, closeup.

[Jan Mrázek]’s success with 3D printing a solder paste stencil is awfully interesting, though he makes it clear that it is only a proof of concept. There are a lot of parts to this hack, so let’s step through them one at a time.

First of all, it turns out that converting a PCB solder paste layer into a 3D model is a bit of a challenge. A tool [Jan] found online didn’t work out, so he turned to OpenSCAD and wrote a script (available on GitHub) which takes two DXF files as input: one for the board outline, and one for the hole pattern. If you’re using KiCad, he has a Python script (also on GitHub) which will export the necessary data.

The result is a 3D model that is like a solder paste mask combined with a raised border to match the board outline, so that the whole thing self-aligns by fitting on top of the PCB. A handy feature, for sure. [Jan] says the model pictured here printed in less than 10 minutes. Workflow-wise, that certainly compares favorably to waiting for a stencil to arrive in the mail. But how do the actual solder-pasting results compare?

3D printed solder stencil on PCB, after applying solder paste.

[Jan] says that the printed stencil had a few defects but it otherwise worked fine for 0.5 mm pitch ICs and 0402 resistors, and the fact that the 3D printed stencil self-registered onto the board was a welcome feature. That being said, it took a lot of work to get such results. [Jan]’s SLA printer is an Elegoo Mars, and he wasn’t able to have it create holes for 0.2 mm x 0.5 mm pads without first modifying his printer for better X/Y accuracy.

In the end, he admits that while a functional DIY solder stencil can be 3D printed in about 10 minutes, it’s not as though professionally-made stencils that give better results are particularly expensive or hard to get. Still, it’s a neat trick that could come in handy. Also, a quick reminder that we stepped through how to make a part in OpenSCAD in the past, which should help folks new to OpenSCAD make sense of [Jan]’s script.

Don’t Scrape Magnet Wire, Do This Instead

March 9, 2020 by Donald Papp 111 Comments

[Tom] doesn’t much like breadboarding. He prefers to wire up prototypes with perfboard and solder point-to-point with enameled magnet wire. That may sound troublesome to some of you, but [Tom] has come up with a few tips to make prototyping with perfboard and magnet wire easier and more effective, and the biggest tip is about how to manage stripping all that magnet wire.

Push the tip of the magnet wire a small distance into the molten solder and hold it there for a few moments. The solder will bubble away the enamel and tin the copper underneath in the process.

Magnet wire is a thin, solid-core conductor that has a clear coating of enamel. This enamel acts as an electrical insulator. The usual way to strip away the enamel and reveal the shiny copper underneath is to scrape it off, but that would get tiresome when working with a lot of connections. [Tom] prefers to “boil it away” with a blob of molten solder on an iron’s tip.

Begin by melting a small amount of solder on the iron, then push the tip of the magnet wire a small distance into the molten solder and hold it there for a few moments. The enamel will bubble away and the solder will tin the copper underneath in the process. The trick is to use fresh solder, and to clean the tip in between applications. You can see him demonstrate this around the 1:00 mark in the video embedded below.

Once the tip of the magnet wire is tinned, it can be soldered as needed. Magnet wire bends well and holds its shape nicely, so routing it and cutting to size isn’t too difficult. [Tom] also suggests a good hands-free PCB holder, and points out that 0603 sized SMT resistors fit nicely between a perfboard’s 0.1″ pads.

Perfboard (and veroboard) have been standbys of prototyping for a long time, but there are still attempts at improving them, usually by allowing one to combine through-hole and surface-mount devices on the same board, but you can see [Tom] demonstrate using magnet wire on plain old perfboard in the video below.

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Blister Pack With Jet Fighter Toy Is A Business Card

March 5, 2020 by Jenny List 20 Comments

In the world of business cards, it seems that for some people a white rectangle of card just doesn’t cut it any more. A card isn’t simply a means to display your contact details, instead it can be a way to show off your work and demonstrate to the world your capabilities. For [agepbiz] those are the skills of a 3D design specialist, so what better way to proceed than by distributing a 3D-printed example of his work? How to render that into a business card? Put it in a retail-style blister pack, of course. Take a look at the video below the break.

It’s an interesting process to follow, because there are certainly readers who will have toyed with the idea of selling their work, and this makes an attractive way to display a small assembly while still keeping it safe from damage. The toy – a small 3D-printed jet fighter with working swing wings that’s a masterpiece in itself – is laid on a backing card and a custom blister is glued over it. The manufacture of the printed backing card with a CNC card cutter is shown, followed by that of the blister with a custom SLA-printed mould being used to vacuum-form a sheet of clear plastic. Surprisingly the whole is assembled with just a glue stick, we’d have expected something with a bit more grab. The result is a professional-looking blister packed product of the type you wouldn’t bat an eyelid over if you saw it in a shop, and one of those things that it’s very useful to have some insight into how one might be made..

It’s possible this card might be a little bulky to slip in your wallet, but it’s hardly the only novelty card we’ve brought you over the years. Some of our most recent favourites run Linux or play Tetris.

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Magnets Make Prototyping E-Textiles A Snap

February 26, 2020 by Kristina Panos 10 Comments

How do you prototype e-textiles? Any way you can that doesn’t drive you insane or waste precious conductive thread. We can’t imagine an easier way to breadboard wearables than this appropriately-named ThreadBoard.

If you’ve never played around with e-textiles, they can be quite fiddly to prototype. Of course, copper wires are floppy too, but at least they will take a shape if you bend them. Conductive thread just wants lay there, limp and unfurled, mocking your frazzled state with its frizzed ends. The magic of ThreadBoard is in the field of magnetic tie points that snap the threads into place wherever you drape them.

The board itself is made of stiff felt, and the holes can be laser-cut or punched to fit your disc magnets. These attractive tie-points are held in place with duct tape on the back side of the felt, though classic double-stick tape would work, too. We would love to see somebody make a much bigger board with power and ground rails, or even make a wearable ThreadBoard on a shirt.

Even though [chrishillcs] is demonstrating with a micro:bit, any big-holed board should work, and he plans to expand in the future. For now, bury the needle and power past the break to watch [chris] build a circuit and light an LED faster than you can say neodymium.

The fiddly fun of e-textiles doesn’t end with prototyping — implementing the final product is arguably much harder. If you need absolutely parallel lines without a lot of hassle, put a cording foot on your sewing machine.

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Flashing Sonoff Devices With Tasmota Gets Easier

February 25, 2020 by Donald Papp 18 Comments

Tasmota is an alternative firmware for ESP boards that provides a wealth of handy features, and [Mat] has written up a guide to flashing with far greater ease by using Tasmotizer. Among other things, it makes it simple to return your ESP-based devices, like various Sonoff offerings, to factory settings, so hack away!

Tasmotizer is a front end that also makes common tasks like backing up existing firmware and setting configuration options like, WiFi credentials, effortless. Of course, one can’t really discuss Tasmotizer without bringing up Tasmota, the alternative firmware for a variety of ESP-based devices, so they should be considered together.

Hacks based on Sonoff devices are popular home automation projects, and [Mat] has also written all about what it was like to convert an old-style theromostat into a NEST-like device for about $5 by using Tasmota. A video on using Tasmotizer is embedded below, so give it a watch to get a head start on using it to hack some Sonoff devices.

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Gear Up Your Gear Knowledge With Gears

February 19, 2020 by Kerry Scharfglass 16 Comments

Gears are fairly straightforward way to couple rotational motion, and the physics topics required to understand them are encountered in an entry level physics classroom, not a university degree. But to really dig down to the root of how gears transfer motion may be somewhat more complex than it seems. [Bartosz Ciechanowski] put together an astonishingly good interactive teaching tool on gears, covering the fundamentals of motion up through multi-stage gear trains.

Illustrating the distance traveled at different points on the disc

The post starts at the beginning – not “how to calculate a gear ratio” – but how does rotational motion work at all. The illustrations help give the reader an intuitive sense for how the rate of rotation is measured and what that measurement actually represents in the real world. From there [Bartosz] builds up to describing how two discs touching edge to edge transfer motion and the relationship of their size on that process. After explaining torque he has the fundamentals in place to describe why gears have teeth, and why they work at all.

Well written explanatory copy aside, the real joy in this post is the interactivity. Each concept is illustrated, and each illustration is interactive. Images are accompanied by a slider which lets you adjust what’s shown, either changing the speed of a rotating gear or advancing the motion of two teeth interlocking. We found that being able to move through time this way really helped form an intuitive understanding of the concepts being discussed. This feels like the dream of interactive multimedia textbooks come to life.