“I Can Reflow” Merit Badge

June 26, 2016 by Elliot Williams 6 Comments

[Nick Sayer] can reflow, and he can prove it. He designed a simple blinking-LED circuit that uses SMD parts to, well, blink LEDs. That’s not the point, though. It’s designed to be a test platform for reflow soldering, and to use a minimum number of valuable parts. Plus, it says “I can reflow!” in exposed copper. What else do you want?

OK, as far as “proving it” goes, the badge isn’t 100% reliable — we hand-solder 0805 components all day long. But still, if you want to try your hand at reflowing a circuit board, and you don’t want to ruin a lot of expensive parts if you fail, something like this is a good idea.

The design is open, and it’s really the idea that’s the point here anyway. How about something that would be really onerous to hand-solder, but still cheap? We’re thinking a matrix of tiny LEDs and a shift register or something.

We just ran an article on a hand-soldering challenge board, this seems the perfect complement. Display both proudly on your desk and confound and amaze your coworkers!

A Fountain Of Superhydrophobic Art

June 24, 2016 by James Hobson 29 Comments

Superhydrophobic coating finds a new application in art through [Arthur Carabott] in the form of a bizarre fountain.

A Master’s student in the Global Innovation Design course at the London Royal College of Art, [Carabott] achieved the effect by leaving parts of the laser-cut acrylic untouched by Rust-oleum’s NeverWet Multisurface coating. A 3d printed spigot mounted high above the surface imparts greater velocity to the impacting water so as it hits the acrylic the liquid forms into channels giving the impression of something surreal. Indeed — his design is inspired by the optical illusions of Japanese mathematician Kokichi Sugihara which attempt to realize the impossible artwork of M.C. Escher. The effect is worthy of a double take.

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The Unity Of Dance And Architecture

June 22, 2016 by James Hobson 7 Comments

In an ambitious and ingenious blend of mechanical construction and the art of dance, [Syuko Kato] and [Vincent Huyghe] from The Bartlett School of Architecture’s Interactive Architecture Lab have designed a robotic system that creates structures from a dancer’s movements that they have christened Fabricating Performance.

A camera records the dancer’s movements, which are then analyzed and used to direct an industrial robot arm and an industrial CNC pipe bending machine to construct spatial artifacts. This creates a feedback loop — dance movements create architecture that becomes part of the performance which in turn interacts with the dancer. [Huyghe] suggests an ideal wherein an array of metal manipulating robots would be able to keep up with the movements of the performer and create a unique, fluid, and dynamic experience. This opens up some seriously cool concepts for performance art.

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Walnut Windfall Winds Up In Custom Keyboard

June 21, 2016 by Dan Maloney 7 Comments

When a neighbor decided to cut down a walnut tree, [voluhar] decided to make something of the wood. The result was this custom keyboard that combines wood and metal in a lovely and functional package.

Walnut is a wood with a rich heritage in consumer electronics. Back in the early days of TV, huge console sets were built into solid walnut cabinets and proudly displayed along with the other fine furnishings in a home. [voluhar]’s keyboard captures a little of that spirit while retaining all the functionality you’d expect. From the custom PCB to the engraved aluminum key caps, it looks like every part was machined with a CNC router. The keyboard sports satisfyingly clicky Cherry MX switches, and a few cleverly positioned LEDs provide subtle feedback on the state of the locking keys. As for the imperfections in the walnut case, we think it just adds to the charm and warmth of the finished product, which would look great on any desktop.

Wood has appeared in a couple of custom keyboards that we’ve featured before, like this all-wood version. But if you want the retro look without the wood, you could always try a keyboard built out of a typewriter.

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Brutal Water Cannon Defeats Summer Heat; Kills It On Documentation

June 21, 2016 by Dan Maloney 21 Comments

There’s a war on, and while this over-the-top water blaster is certainly an escalation in the Water Wars arms race, that’s not the war we’re referring to. We’re talking about the Documentation War. Hackers, you’re on notice.

If you want to see how a project should be documented, look no further than [Tim]’s forum posts over at WaterWar.net. From the insanely detailed BOM with catalog numbers and links to supplier websites, to scads of build photos with part number callouts, to the finely detailed build instructions, [Tim] has raised the stakes for anyone that documents any kind of build.

And that’s not even touching on the merits of the blaster itself, which has air and water tanks plumbed with every conceivable valve and fitting. There’s even an inline stream straightener made of bundled soda straws to keep the flow as laminar as possible. It looks like [Tim] and his colleagues are obsessed with launching streams of water as far as possible, and although bad weather has prevented an official measurement so far, from the video below it sure looks like he’s covering a huge distance with a stream that stays mostly intact to deliver the full blast to its intended target without losing a drop.

For as much fun as amped-up water guns appear to be, we haven’t seen too many grace these pages before. Going way back we covered a DIY super-soaker. For something much less involved than [Tim’s] masterpiece, you can pull together this pressurized water pistol in an afternoon.

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Micro Tesla Turbine Is An Engineering Tour De Force

June 17, 2016 by Dan Maloney 64 Comments

A corollary to Godwin’s Law ought to be that any Hackaday post that mentions Nikola Tesla will have a long and colorful comment thread. We hope this one does too, but with any luck it’ll concentrate on the engineering behind this tiny custom-built Telsa turbine.

For those not familiar with Mr. Tesla’s favorite invention, the turbine is a super-efficient design that has no blades, relying instead on smooth, closely spaced discs that get dragged along by the friction of a moving fluid. [johnnyq90]’s micro version of the turbine is a very accomplished feat of machining. Although at first the build appears a bit janky, as it progresses we see some real craftsmanship – if you ever doubt that soda can aluminum can be turned, watch the video below. The precision 25mm rotor goes into a CNC machined aluminum housing; the way the turned cover snaps onto the housing is oddly satisfying. It looks like the only off-the-shelf parts are the rotor bearings; everything else is scratch-made. The second video ends with a test spool-up that sounds pretty good. We can’t wait for part 3 to find out how fast this turbine can turn.

Size matters, and in this case, small is pretty darn impressive. For a larger treatment of a Tesla turbine, see this one made of old hard drive platters.

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Wheel Of Resistors Form Unique Rotary Encoder

June 15, 2016 by Dan Maloney 75 Comments

Continuing his tradition of making bits of wire and scraps of wood work wonders, [HomoFaciens] is back with a unique and clever design for an electromechanical encoder.

There are lots of ways to build an encoder, and this is one we haven’t seen before. Not intended in any way to be a practical engineered solution, [HomoFaciens]’ build log and the video below document his approach. Using a rotating disc divided into segments by three, six or eight resistors, the encoder works by adding each resistor into a voltage divider as the disc is turned. An Arduino reads the output of the voltage divider and determines the direction of rotation by comparing the sequence of voltages. More resistors mean higher resolution but decreased maximum shaft speed due to the software debouncing of the wiped contacts. [HomoFaciens] has covered ground like this before with his tutorial on optical encoders, but this is a new twist – sort of a low-resolution continuous-rotation potentiometer. It’s a simple concept, a good review of voltage dividers, and a unique way to sense shaft rotation.

Is this all really basic stuff? Yep. Is it practical in any way? Probably not, although we’ll lay odds that these encoders find their way into a future [HomoFaciens] CNC build. Is it a well-executed, neat idea? Oh yeah.

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