A Buzzing, Flashing Phone Ringer For The Elderly

October 11, 2023 by Kristina Panos 8 Comments

For a lonely person, elderly or otherwise, the sound of a ringing phone can be music to the ears, unless of course it’s another spam call. But what good is a phone when you can’t hear it well enough to answer?

[Giovanni Aggiustatutto] was tasked with building an additional ringer for a set of cordless landline phones belonging to an elderly friend. Rather than try to intercept the signal, [Giovanni] chose to simply mic up the phone base that’s connected to the phone port on the router and send a signal over Wi-Fi to a second box which has a loud piezo buzzer and a handful of LEDs.

At the heart of this build is a pair of ESP8266 Wemos D1 minis and an Arduino sound sensor module inside a pair of really nice-looking 3D printed boxen that may or may not have been inspired by an IKEA air quality sensor. On the receiving side, a green LED indicates the system is working, and the red LEDs flash as soon as a call comes in.

All the code, schematics, and STL files are available for this build, and between the Instructable and the build video after the break, you should have no trouble replicating it for the hard-of-hearing in your life.

Continue reading “A Buzzing, Flashing Phone Ringer For The Elderly” →

Polish Up Your Product With Graphic Overlays

October 8, 2023 by Donald Papp 17 Comments

[Kevin Hunckler] recently did some in-house manufacturing for a product and shared his experiences in adding high-quality custom graphic overlays or acrylic panels to give the finished units a professional look. The results look great and were easy to apply, making his product more attractive without needing much assembly work.

A graphic overlay with transparent areas, a cutout, and adhesive backing to fit an off-the-shelf Hammond enclosure.

Sadly, when doing initial research he was disappointed to find very little information on the whole process. While in the end it isn’t terribly complex, it still involved a lot of trial and error before he zeroed in on what the suppliers in the industry expect. Fortunately, everything can be done with tools most hackers probably already have access to.

The process seems to us somewhat reminiscent of having PCBs manufactured. One defines the product housing, outlines the overlay, creates the artwork, defines an adhesive layer, and makes a design document explaining each layer and important feature. [Kevin] provides examples of his work, one of which fits an off-the-shelf Hammond enclosure.

Professionally-made acrylic panels or graphic overlays is something worth keeping in mind for hobbyists and those who might engage in desktop manufacturing, as long as the costs are acceptable. Rather like PCBs, costs go down as quantities go up. [Kevin]’s 50 mm x 50 mm overlay cost about 1 USD each in quantity 200, but only 0.50 USD each when buying 500.

These may be great for low or middling quantities, but that doesn’t mean one is out of options for prototypes or micro quantities. We have seen fantastic results adding full-color images to 3D prints, and even using a 3D printer to draw labels directly onto prints.

2023 Halloween Hackfest: Treat Trough Of Terror Is Actually Pretty Cute

October 3, 2023 by Kristina Panos 7 Comments

Even though it seems the worst of COVID has passed, October generally kicks off cold and flu season, so why not continue to pass out Halloween treats in a socially-distanced fashion?

That is, of course the idea behind [Gord Payne]’s Halloween Treat Trough of Terror. Lay a treat at the top of the trough and it will activate the LED strips that follow the treat down to the end, as well as some spooky sounds. The treat in question is detected by an SR-04 ultrasonic distance sensor connected to an Arduino Nano.

All in all this was a highly successful build as far as neighborhood entertainment value goes. Toddlers stared in awe at the blinkenlights, teenagers proclaimed it ‘sick’, and we can only assume that the adults were likely happy to see something aimed at kids that’s not scary.

[Gord] has a nice how-to if you want to build your own, and of course, the Arduino sketch is available. Be sure to check it out in action after the break.

Don’t have room to build a treat slide? Here’s a socially-distanced dispenser that lets them stomp a giant button.

Continue reading “2023 Halloween Hackfest: Treat Trough Of Terror Is Actually Pretty Cute” →

These DIY Super Headphones Take Sound Seriously

October 1, 2023 by Donald Papp 24 Comments

[Pete Lewis] from SparkFun takes audio and comfort seriously, and recently shared details on making a customized set of Super Headphones, granting quality sound and stereo ambient passthrough, while providing hearing protection at the same time by isolating the wearer from the environment.

Such products can be purchased off the shelf (usually called some variant of “electronic hearing protection”), but every hacker knows nothing beats some DIY to get exactly the features one wants. After all, off-the-shelf solutions are focused on hearing protection, not sound quality. [Pete] also wanted features like the ability to freely adjust how much ambient sound was mixed in, as well as the ability to integrate a line-level audio source or Bluetooth input.

Early prototype of Super Headphones (click to enlarge)

On the surface the required components are straightforward, but as usual, the devil is in the details. Microphone selection, for example, required a lot of testing. A good microphone needed to be able to deal with extremely loud ambient sounds without distortion, yet still be sensitive enough to be useful. [Pete] found a good solution, but also muses that two sets of microphones (one for loud environments, and one for quieter) might be worth a try.

After several prototypes, the result is headphones that allow safe and loud band practice in a basement as easily as they provide high-quality music and situational awareness while mowing the lawn. Even so, [Pete]’s not done yet. He’s working on improving comfort by using photogrammetry to help design and 3D print custom-fitted components.

Powder Your Prints For Baby-Smoothness

September 24, 2023 by Kristina Panos 46 Comments

Layer lines are a dead giveaway to non-normies that a thing was 3D printed. There are things you can do to smooth them — sanding, chemical smoothing, and fillers come to mind. Although this technique technically uses all three, it starts with something very simple.

In the video after the break, [DaveRig] gets right to the point: baby powder and resin mixed together make a fine smoothing agent when cured. Having read about it online, he decided to give it a try.

Starting with a half sphere that had admittedly pretty big layer lines, [DaveRig] mixed up enough resin and baby powder to make the consistency of milk or cream. Then he put five coats on, curing and sanding with 120 in between each one.

Then it’s on to standard post-processing stuff. You know, wipe it down with alcohol, sand it a little more, wet sand, and then it’s on to the airbrush and clear-coat. The end result looks to be as smooth as your average bowling ball, as you can see in the main photo.

What’s your favorite post-processing method? Have you tried annealing them in salt?

Continue reading “Powder Your Prints For Baby-Smoothness” →

This Keyboard Doesn’t Work Without Game Boy Cartridges

September 11, 2023 by Kristina Panos 9 Comments

Just when we though we’d seen it all when it comes to custom keyboards (or most of it, anyway), along comes [Stu] with the TypeBoy and TypePak. Like the title implies, TypeBoy and TypePak are inseparable.

Let’s talk about TypePak first. Somehow, some way, [Stu] managed to fit the following into an aftermarket Game Boy Advance cartridge: a XIAO BLE microcontroller, a Sharp Memory Display, a shift register, and a LiPo battery. It’s all there in [Stu]’s incredibly detailed blog post linked above.

Amazing, no? And although [Stu] claims that the TypePak is mostly for aesthetics (boy howdy), it will make swapping microcontrollers much easier in the future.

If this looks sort of familiar, you may remember a likely render of [mujimaniac]’s board called the GIGA40 that also employed a cartridge system. Allegedly there is now a working prototype of the GIGA40.

Would you like to give the TypeBoy and TypePak a go? Files are available on GitHub, but this doesn’t seem like a project for the faint of heart.

Speaking of stuffing things in to Game Boy cartridges, check out this SNES cartridge turned hard drive enclosure.

Via KBD

3D-Printed Woven Coasters Save Tabletops In Style

August 20, 2023 by Kristina Panos 6 Comments

When regular people think of 3D printing, they likely imagine semi-newfangled objects like twisty vases and useless trinkets. But there is so much more to 3D printing, as [andrei.erdei]’s printed, woven coasters demonstrate.

The design is based on the stake and strand basket weaving technique, which uses rigid strips called stakes in one direction and thinner strips called strands in the other. Since the flexibility of PLA is questionable, [andrei] printed the stakes already bent in a square wave pattern that accommodates the strands fairly easily. To tie the coasters together and make them look more polished and commercial, [andrei] designed a holder as well.

The awesome thing about this technique is that you can do so much with it, like varying the stakes’ widths or making them diagonal instead of square. [andrei] designed these in Tinkercad using Codeblocks; of course, they are open source. Be sure to check out the assembly video after the break.

Continue reading “3D-Printed Woven Coasters Save Tabletops In Style” →