Pouring 1200° Tea: Foundry In A Fire Extinguisher

August 15, 2017 by Dan Maloney 29 Comments

Let’s face it — the design of most home foundries leaves something to be desired. Most foundries are great at melting metal, but when it comes to pouring the melt, awkward handling can easily lead to horrific results. That’s why we appreciate the thought that went into this electric melting pot foundry.

Sure, electric foundries lack some of the sex-appeal of gas- or even charcoal-fueled foundries, but by eschewing the open flames and shooting sparks, [Turbo Conquering Mega Eagle] was able to integrate the crucible into the foundry body and create what looks for all the world like a Thermos bottle for molten aluminum.

The body is a decapitated fire extinguisher, while the crucible appears to just be a length of steel pipe. An electric stove heating element is wrapped around the crucible, PID control of which is taken care of by an external controller and solid state relay. Insulated with Pearlite and provided with a handle, pours are now as safe as making a nice cup of 1200° tea.

You’ll perhaps recall that [Turbo Conquering Mega Eagle] has a thing for electric foundries, although we have to say the fit and finish of the current work far exceeds his previous quick-and-dirty build using an old electric stove.

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Manually-Adjustable Three-Axis Gimbal

August 12, 2017 by John Baichtal 3 Comments

[Tim Good] built a 3-axis gimbal out of 3D-printed and machined pieces, and the resulting design is pretty sweet, with a nice black-on-black look. He machined the flat pieces because they were too long to be printed in his 3D-printer.

The various axes swivel on four bearings each, and each ring features a manual locking mechanism made out of steel stainless pins that immobilize each axis. The gimbal operation itself appears to be manual. That said, [Tim] used 12-wire slip rings to power whatever camera gets mounted on it–it looks like the central enclosure could hold a camera the size of a GoPro.

[Tim] has shared his design files on Thingiverse: it’s a complicated build with 23 different files. This complexity got us wondering: aren’t there two pitch axes?

We definitely love seeing gimbal projects here on Hackaday. A few cases in point, a gimbal-mounted quadcopter, another project with a LIDAR added to a camera gimbal, and this gimbal-mounted coffee cup.

Turning And Burning With A CNC Pyrography Machine

August 11, 2017 by Dan Maloney 11 Comments

With CNC machines, generally the more axes the better. Three-axis machines with a vertical quill over a rectangular workspace are de rigueur, and adding an axis or two can really step up the flexibility of a machine. But can only two axes be of any use? Sure can, as witnessed by this two-axis CNC wood burning machine.

As [tuckershannon] tells the tale, this was a newbie build aided by the local hackerspace. Axis one is a rotary table of laser-cut wood gears powered by a stepper. Axis two is just a stepper and lead screw sitting on a couple of blocks of wood. A Raspberry Pi under the hood controls the motors and cycles the pyrography pen on and off as it scans across a piece of wood on the rotary table, burning a spiral pattern that makes for some interesting art. Hats off to [tuckershannon] for figuring out the math needed to adapt to the changing speed of the pen over the wood as the diameter gets bigger.

We love this build, can’t help but wonder if some clever gearing could eliminate the need for the second stepper. And perhaps an upgrade from the standard resistive wood burner to an arc lighter pyrography pen would improve resolution. Still, it’s hard to argue with results, and this is a great hack.

[via r/raspberrypi]

Thanks to [Liz] for the tip!

You Know You Can Do That With A 555

August 10, 2017 by Al Williams 34 Comments

Hardly a week goes by that we don’t post a project where at least one commenter will lament that the hacker could have just used a 555. [Peter Monta] clearly gets that point of view. For a 555 design contest, he created both digital logic gates and an op amp, all using 555 chips. We can’t quite imagine the post apocalyptic world where the only surviving electronic components are 555 chips, but if that day were to come, [Peter] is your guy.

Using the internal structure of the 555, [Peter] formed a basic logic gate, an inverter, latches, and more. He also composed things like counters and seven-segment decoders. He had a very simple 4-bit CPU design in Verilog that he was going to attempt until he realized it would map into almost 400 chips (half of that if you’d use a dual 555, but still). If you built this successfully, we would probably post it, by the way. You can see a video of the digital logic counter, below.

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Silicone Molds For Stove-Top Metal Casting

August 9, 2017 by Dan Maloney 25 Comments

Casting metal parts from 3D-printed plastic or Styrofoam models is all the rage these days, and for good reason — casting is a way to turn one-offs into mass-produced parts. Seems like most of the metal casting projects we feature are aluminum in sand molds, though, so it’s refreshing to see a casting project using silicone molds to cast low-melting point metals.

Don’t get us wrong — sand-cast aluminum is a great method that can even be used to build a lathe from scratch. But not everyone wants to build a foundry and learn the sometimes fussy craft of creating sand molds. [Chris Deprisco] wanted to explore low-melting point bismuth alloys and set about making silicone rubber molds of a 3D-printed Maltese falcon. The bismuth-tin alloy, sold as a substitute for casting lead fishing weights, melts on at 281°F (138°C) and is cool enough for the mold to handle. Initial problems with bubbles in the cast led to a pressure vessel fix, and a dull, grainy surface was fixed by warming the mold before the pour. And unlike sand molds, silicone molds are reusable.

Of course if aluminum is still your material of choice, there’s no need for a complicated foundry. A tuna can, a loaf of bread, and a handful of play sand is all you need to make custom parts.

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A Hypnotizing Interactive Art Piece For Visualizing Color Theory

August 8, 2017 by Cameron Coward 4 Comments

Digital color theory can be a tricky concept to wrap one’s mind around – particularly if you don’t have experience with digital art. The RGB color model is about as straightforward as digital color mixing gets: you simply set the intensity of red, green, and blue individually. The result is the mixing of the three colors, based on their individual intensity and the combined wavelength of all three. However, this still isn’t nearly as intuitive as mixing paint together like you did in elementary school.

To make RGB color theory more tangible, [Tore Knudsen and Justin Daneman] set out to build a system for mixing digital colors in a way that reflects physical paint mixing. Their creation uses three water-filled containers (one each for red, green, and blue) to adjust the color on the screen. The intensity of each color is increased by pouring more water into the corresponding container, and decreased by removing water with a syringe.

An Arduino is used to detect the water levels, and controls what the user sees on the screen. In one mode, the user can experiment with how the color levels affect the way a picture looks. The game mode is even more interesting, with the goal being to mix colors to match a randomly chosen color that is displayed on the screen.

The practical applications for this project may be somewhat limited, but as an interactive art piece it’s hypnotizing. And, it may just help you with understanding RGB colors for your next project.

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Imaging Magnetism With A Hall Effect Camera

August 7, 2017 by Brian Benchoff 54 Comments

[Peter Jansen] is the creator of the Open Source Tricorder. He built a very small device meant to measure everything, much like the palm-sized science gadget in Star Trek. [Peter] has built an MRI machine that fits on a desktop, and a CT scanner made out of laser-cut plywood. Needless to say, [Peter] is all about sensing and imaging.

[Peter] is currently working on a new version of his pocket-sized science tricorder, and he figured visualizing magnetic fields would be cool. This led to what can only be described as a camera for magnetism instead of light. It’s a device that senses magnetic fields in two directions to produce an image. It’s cool, and oddly, electronically simple at the same time.

Visualizing magnetic fields sounds weird, but it’s actually something we’ve seen before. Last year, [Ted Yapo] built a magnetic imager from a single magnetometer placed on the head of a 3D printer. The idea of this device was to map magnetic field strength and direction by scanning over the build platform of the printer in three dimensions. Yes, it will create an image of field lines coming out of a magnet, but it’s a very slow process.

Instead of using just one magnetic sensor, [Peter] is building a two-dimensional array of magnetic sensors. Basically, it’s just a 12×12 grid of Hall effect sensors wired up to a bunch of analog multiplexers. It’s a complicated bit of routing, but building the device really isn’t hard; all the parts are easily hand-solderable.

While this isn’t technically a camera as [Peter] would need box or lens for that, it is a fantastic way to visualize magnetic fields. [Peter] can visualize magnets on his laptop screen, with red representing a North pole and green representing the South pole. Apparently, transformers and motors look really, really cool, and this is a perfect proof of concept for the next revision of [Peter]’s tricorder. You can check out a video of this ‘camera’ in action below.

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