Discarded Plastic Laser-Cut And Reassembled

July 2, 2021 by Bryan Cockfield 15 Comments

The longevity of plastic is both a blessing and a curse. On the one hand, it’s extremely durable, inexpensive, and easy to work with, but it also doesn’t biodegrade and lasts indefinitely in the environment when not disposed of properly. While this can mean devastating impacts to various ecosystems, it can also be a benefit if you happen to pick this plastic up and also happen to have a laser cutter around.

After cleaning and sorting plastic that they had found from various places, including scraps from a 3D printing facility, the folks at [dinalab] set about turning waste plastic into something that would be usable once more. After sorting it they shredded it and then melted it into sheets. They found that a sandwich press yielded the best results, as it kept the plastic at a low enough temperature to keep it from burning. Once its off of the press and properly cooled, the flat sheets of plastic can be sent to the laser cutter to be made into whatever useful thing they happen to need.

Not only does this process reuse plastic that would otherwise end up in the landfill (or worse, the ocean), it can also reuse plastic from itself since the scraps can be re-melted back into sheets. Plastic does lose some of its favorable material properties with repeated heat cycles, but we’d have to imagine this is negligible for the types of things that [dinalab] is creating. Of course, you can always skip the heat cycles entirely and turn waste plastic directly into 3D printer filament instead.

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Automate The Farm With Acorn

July 1, 2021 by Bryan Cockfield 40 Comments

Farming has been undergoing quite a revolution in the past few years. Since World War 2, most industrial farming has relied on synthetic fertilizer, large machinery, and huge farms with single crops. Now there is a growing number of successful farmers bucking that trend with small farms growing many crops and using natural methods of fertilizing that don’t require as much industry. Of course even with these types of farms, some machinery is still nice to have, so this farmer has been developing an open-source automated farming robot.

The robot is known as Acorn and is the project of [taylor] who farms in California. The platform is powered by an 800 watt solar array feeding a set of supercapacitors for energy storage. It uses mountain bike wheels and tires fitted with electric hub motors which give it four wheel drive and four wheel steering to make it capable even in muddy fields. The farming tools, as well as any computer vision and automation hardware, can be housed under the solar panels. This prototype uses an Nvidia Jetson module to handle the heavy lifting of machine learning and automation, with a Raspberry Pi to handle the basic operation of the robot, and can navigate itself around a farm using highly precise GPS units.

While the robot’s development is currently ongoing, [taylor] hopes to develop a community that will build their own versions and help develop the platform. Farming improvements like this are certainly needed as more and more farmers shift from unsustainable monocultures to more ecologically friendly methods involving multiple simultaneous crops, carbon sequestration, and off-season cover crops. It’s certainly a long row to hoe but plenty of people are already plowing ahead.

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You Can’t Put The Toothpaste Back In The Tube, But It Used To Be Easier

June 24, 2021 by Kristina Panos 60 Comments

After five years of research, Colgate-Palmolive recently revealed Australia’s first recyclable toothpaste tube. Why is this exciting? They are eager to share the design with the rest of the toothpaste manufacturers and other tube-related industries in an effort to reduce the volume of plastic that ends up in landfills. It may not be as life-saving as seat belts or the Polio vaccine, but the move does bring Volvo and OG mega open-sourcer Jonas Salk to mind.

Today, toothpaste tubes are mostly plastic, but they contain a layer of aluminum that helps it stay flattened and/or rolled up. So far, multi-layer packaging like this isn’t accepted for recycling at most places, at least as far as Australia and the US are concerned. In the US, Tom’s of Maine was making their tubes entirely out of aluminum for better access to recycling, but they have since stopped due to customer backlash.

Although Colgate’s new tubes are still multi-layered, they are 100% HDPE, which makes them recyclable. The new tubes are made up of different thicknesses and grades of HDPE so they can be easily squeezed and rolled up.

Toothpaste Before Tubes

Has toothpaste always come in tubes? No it has not. It also didn’t start life as a paste. Toothpaste has been around since 5000 BC when the Egyptians made tooth powders from the ashes of ox hooves and mixed them with myrrh and a few abrasives like powdered eggshells and pumice. We’re not sure what they kept it in — maybe handmade pottery with a lid, or a satchel made from an animal’s pelt or stomach.

The ancient Chinese used ginseng, salt, and added herbal mints for flavoring. The Greeks and Romans tried crushed bones, oyster shells, tree bark, and charcoal, which happens to be back in vogue. There is evidence from the late 1700s showing that people once brushed with burnt breadcrumbs.

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The Regulatory Side Of Rolling Your Own Moderate Solar Farm

June 17, 2021 by Donald Papp 25 Comments

[Russell Graves] lives in Idaho and recently connected his solar installation to the grid, which meant adhering to regulatory requirements for both the National Electric Code (NEC) as well as complying with the local power company’s own regulations. His blog post is an interesting look at the whole regulatory process and experience, and is of interest to anyone curious about running their own solar farm, whether they have plans to connect it to the grid or not.

A circuit breaker that met NEC code, but not the power company’s requirements.

The power company has a very different set of priorities from the NEC, and part of [Russell]’s experience was in having to meet requirements that weren’t documented in the expected places, so study of the materials didn’t cut it. In particular, the power company needed the system to have disconnects with conductors that visually move out of position when disconnected. [Russell] was using NEC-compliant circuit breakers that met NEC code, but they didn’t meet the power company requirement for conductors that can be visually confirmed as being physically disconnected. Facing a deadline, [Russell] managed to finesse a compliant system that was approved, and everything got signed off just as winter hit.

How well does his solar farm work out? Sometimes the panels produce a lot of power, sometimes nearly nothing, but it has been up and running for all of winter and into spring. Over the winter, [Russell] pulled a total of 3.1 MWh from the grid, mainly because his home is heated with electric power. But once spring hit, he started pushing considerably more into the grid than he was pulling; on some days his setup produces around 95 kWh, of which about 70 kWh gets exported.

[Russell] didn’t go straight to setting up his own modest solar farm; we saw how he began by making his own ideal of a perfect off-grid office shed that ran on solar power, but it has certainly evolved since then and we’re delighted to see that he’s been documenting every bit of the journey.

Sawdust Printer Goes Against The Grain By Working With Wood Waste

June 13, 2021 by Kristina Panos 28 Comments

Wood-infused filament has been around for awhile now, and while it can be used to create some fairly impressive pieces, the finished product won’t fool the astute observer. For one thing, there’s no grain to it (not that every piece needs to show grain). For another, you can’t really throw it on a fire for emergency heating like you could with actual wood.

But a company called Desktop Metal has created a new additive manufacturing process for wood and paper waste called Forust (get it?) that gets a lot closer to the real thing. It might be an environmental savior if it catches on, though that depends on what it ends up being good for.

The company’s vision is to produce custom and luxury wood products — everything from sophisticated pencil cups to stunning furniture, and to take advantage of the nearly limitless geometry afforded by additive manufacturing. Forust uses the single-pass binder jetting method of 3D printing to lay down layers of sawdust and lignin and then squirt out some glue in between each one to hold them together.

Although Desktop Metal doesn’t mention a curing process for Forust in their press release, post-processing for solidity and longevity is the norm in binder jetting, which is usually done with ceramic or metal-based materials.

Let’s talk about those wood grains. Here’s what the press release says:

Digital grain is printed on every layer and parts can then be sanded, stained, polished, dyed, coated, and refinished in the same manner as traditionally-manufactured wood components. Software has the ability to digitally reproduce nearly any wood grain, including rosewood, ash, zebrano, ebony and mahogany, among others. Parts will also support a variety of wood stains at launch, including natural, oak, ash, and walnut.

Beauty and workability are one thing. But this will only be worthwhile if the pieces are strong. This is something that isn’t too important for pencil holders, but is paramount for furniture. Forust’s idea is to ultimately save the trees, but how are they going to get sawdust and lignin without the regular wood industry — they want to be circular and envision recycling of their goods at end-of-life into new goods

We wondered if the wood waste printer would ever become a thing. You know, there’s more than one way to print in sawdust — here’s a printer that stacks up layers of particle boards and carves them with a CNC.

Images via Forust

Electric Vehicles Could Be The Grid Storage Solution We’ve Been Dreaming Of

June 7, 2021 by Lewin Day 157 Comments

As nation states grapple with the spectre of environmental and economic losses due to climate change, we’ve seen an ever greater push towards renewable energy sources to replace heavier polluters like coal and natural gas. One key drawback of these sources has always been their intermittent availability, spurring interest in energy storage technologies that can operate at the grid level.

With the rise in distributed energy generation with options like home solar power, there’s been similar interest in the idea of distributed home battery storage. However, homeowners can be reluctant to make investments in expensive batteries that take years to pay themselves off in energy savings. But what if they had a giant battery already, just sitting outside in the driveway? Could electric vehicles become a useful source of grid power storage? As it turns out, Ford wants to make their electric trucks double as grid storage batteries for your home.

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Sailing Faster Than The Wind Itself

June 6, 2021 by Jenny List 136 Comments

If you search the outer reaches of the internet you will find all sorts of web sites and videos purporting to answer to free energy in the form of perpetual motion machines and other fantastical structures that bend the laws of physics to breaking point. We’d love them to be true but we have [Émilie du Châtelet] and her law of conservation of energy to thank for dashing those hopes. So when along comes a machine that appears to violate a fundamental Law of Physics, it’s reasonably met with skepticism. But the wind-powered vehicle built by [Rick Cavallaro] looks as though it might just achieve that which was previously thought impossible. It’s a machine that can move with the wind at a speed faster than the wind itself.

A fundamental law of sailing boats is that when they are sailing with the wind, i.e. in the same direction as the wind, they can’t sail faster than the wind itself. Sailing boats can go faster than the wind powering them by sailing across it at an angle to create lift from their sails, but this effect doesn’t work as the angle tends towards that of the wind.

The vehicle in the video below the break is a sleek and lightweight machine with a large propeller above it, which we are told is not the windmill power source we might imagine it to be. Instead it mimics the effect of a pair of sailing boats sailing across the wind in a spiral around a long cylinder, and thus becomes in effect a fan when turned by the motoin in the craft’s wheels. The drive comes from the wind working on the craft itself, and thus as can be seen from the motion of a streamer on its front, it can overtake the wind. It seems too good to be true at first sight but the explanation holds water. Now we want a ride too!

For fairly obvious reasons, the fantastical world of pseudo-physics isn’t our bag here at Hackaday. But if something might hold promise we’ll at least give it a look. Not all such things we cover turn out to change those Laws of Physics, though.

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