3D Printering: To Print Stainless, You Do Half The Work

February 25, 2021 by Al Williams 37 Comments

Everyone wants to print using metal. It is possible, but the machines to do the work are usually quite expensive. So it caught our eye when MakerBot announced a printer — armed with an experimental extruder — that can print stainless steel parts. Then we read a bit more and realized that it can only sort of do the job. It needs a lot of help. And with some reasonable, if not trivial, modifications, your printer can probably print metal as well.

The key part of the system is BASF Ultrafuse 316L Stainless Steel filament, something that’s been around for a few years. This is a polymer with metal incorporated into it. This explains the special extruder, since metal-bearing filament is hell on typical 3D printer nozzles. However, what comes out isn’t really steel — not yet. For that, you have to send the part to a post-processing facility where it is baked at 1380 °C in a pure hydrogen atmosphere using special equipment. This debinding and sintering produces a part that the company claims can be up to 96% pure metal.

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What If I Never Make Version Two?

February 25, 2021 by Kristina Panos 62 Comments

When you make something, what does version one look like? What I mean is, how much thought do you put into the design? Do you try to make it look nice as you go along, or do you just build something that functions and say screw the presentation? Do you try to solve for everything upfront, or just plow through it and promise to fix your mistakes in version two? What if you never make version two?

No matter what you like to make, there’s a first time for everything. And it doesn’t seem to matter if you need the thing you’re making or just want to have it around: it’s a given that version one will probably be a bit rough around the edges. That’s just how it goes. Even if you’re well-versed in a skill, when you try a new type of project or a new pattern, it will be a new experience. For example, I’ve sewn a dozen different purses, but when I took on a new challenge I found I was only somewhat prepared to make my first backpack.

Great is the enemy of good, and perfection is the enemy of progress. Shooting for a pristine prototype on the first go steep and rocky path that never leads to finishing the build. So our goal here is to decide what makes rev1 good enough that we still love it, even if rev2 never happens.

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Real-Time OS Basics: Picking The Right RTOS When You Need One

February 24, 2021 by Maya Posch 60 Comments

When do you need to use a real-time operating system (RTOS) for an embedded project? What does it bring to the table, and what are the costs? Fortunately there are strict technical definitions, which can also help one figure out whether an RTOS is the right choice for a project.

The “real-time” part of the name namely covers the basic premise of an RTOS: the guarantee that certain types of operations will complete within a predefined, deterministic time span. Within “real time” we find distinct categories: hard, firm, and soft real-time, with increasingly less severe penalties for missing the deadline. As an example of a hard real-time scenario, imagine a system where the embedded controller has to respond to incoming sensor data within a specific timespan. If the consequence of missing such a deadline will break downstream components of the system, figuratively or literally, the deadline is hard.

In comparison soft real-time would be the kind of operation where it would be great if the controller responded within this timespan, but if it takes a bit longer, it would be totally fine, too. Some operating systems are capable of hard real-time, whereas others are not. This is mostly a factor of their fundamental design, especially the scheduler.

In this article we’ll take a look at a variety of operating systems, to see where they fit into these definitions, and when you’d want to use them in a project. Continue reading “Real-Time OS Basics: Picking The Right RTOS When You Need One” →

Increasing The Resolution Of The Electrical Grid

February 24, 2021 by Matthew Carlson 68 Comments

As a society in the USA and other parts of the world, we don’t give much thought to the twisting vines of civilization that entangle our skies and snake beneath our streets. The humming electrical lines on long poles that string our nations together are simply just there. Ever-present and immutable. We expect to flick the switch and power to come on. We only notice the electrical grid when something goes wrong and there is a seemingly myriad number of ways for things to go wrong. Lighting strikes, trees falling on lines, fires, or even too many people trying to crank on the A/C can all cause rolling blackouts. Or as we found out this month, cold weather can take down generation systems that have not been weatherized.

We often hear the electrical grid described as aging and strained. As we look to the future and at the ever-growing pressure on the infrastructure we take for granted, what does the future of the electrical grid look like? Can we move past blackouts and high voltage lines that criss-cross the country?

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Paul Taylor Opened The Lines Of Telecommunication For The Hearing-Impaired

February 23, 2021 by Kristina Panos 23 Comments

These days, nearly everyone communicates through some kind of keyboard, whether they are texting, emailing, or posting on various internet discussion forums. Talking over the phone is almost outmoded at this point. But only a few decades ago, the telephone was king of real-time communication. It was and still is a great invention, but unfortunately the technology left the hearing and speaking-impaired communities on an island of silence.

Paul and an early TDD. Image via Rochester Institute of Technology

Engineer and professor Paul Taylor was born deaf in 1939, long before cochlear implants or the existence of laws that called for testing and early identification of hearing impairment in infants. At the age of three, his mother sent him by train to St. Louis to live at a boarding school called the Central Institute for the Deaf (CID).

Here, he was outfitted with a primitive hearing aid and learned to read lips, speak, and use American sign language. At the time, this was the standard plan for deaf and hearing-impaired children — to attend such a school for a decade or so and graduate with the social and academic tools they needed to succeed in public high schools and universities.

After college, Paul became an engineer and in his free time, a champion for the deaf community. He was a pioneer of Telecommunications Devices for the Deaf, better known as TDD or TTY equipment in the US. Later in life, he helped write legislation that became part of the 1990 Americans with Disabilities Act.

Paul was diagnosed with Alzheimer’s in 2017 and died in January of 2021 at the age of 81. He always believed that the more access a deaf person had to technology, the better their life would be, and spent much of his life trying to use technology to improve the deaf experience.

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Flapping Wings And The Science Of How Bees Can Fly

February 22, 2021 by Zoe Skyforest 70 Comments

Jerry Seinfeld launched his career with Bee Movie, an insect-themed animated feature that took the world by storm in 2007. It posed the quandary – that supposedly, according to all known laws of aviation, bees should not be able to fly. Despite this, the bee flies anyway, because bees don’t care what humans think is impossible.

The quote isn’t easily attributed to anyone in particular, but is a cautionary tale about making the wrong assumptions in an engineering context. Yes, if you model a bee using the same maths as an airliner, of course you’ll find that it shouldn’t be able to fly. Its tiny wings can’t possibly generate enough lift to get its body off the ground. But that’s because the assumption is an erroneous one – because bees don’t fly in the same way planes do. Bees flap their wings. But that’s just the beginning. The truth is altogether more complex and interesting! Continue reading “Flapping Wings And The Science Of How Bees Can Fly” →

A Brief History Of Viruses

February 22, 2021 by Will Sweatman 23 Comments

It was around the year 1590 when mankind figured out how to use optical lenses to bring into sight things smaller than the natural eye can observe. With the invention of the microscope, a new and unexplored world was discovered. It will likely be of great surprise to the reader that scientists of the time did not believe that within this new microscopic realm lay the source of sickness and disease. Most would still hold on to a belief of what was known as Miasma theory, which dates back to the Roman Empire. This theory states that the source of disease was contaminated air through decomposing organic materials. It wouldn’t be until the 1850’s that a man by the name of Louis Pasteur, from whom we get “pasteurization”, would promote Germ Theory into the spotlight of the sciences.

Louis Pasteur experimenting in his lab. — Louis Pasteur. Source

Pasteur, considered by many as the father of microbiology, would go on to assist fellow biologist Charles Chameberland in the invention of the aptly named Pasteur Chamberland filter — a porcelain filter with a pore size between 100 and 1000 nanometers. This was small enough to filter out the microscopic bacteria and cells known at that time from a liquid suspension, leaving behind a supply of uncontaminated water. But like so many other early scientific instrumentation inventions it would lead to the discovery of something unexpected. In this case, a world far smaller than 100 nanometers… and add yet another dimension to the ever-shrinking world of the microscopic.

This is when we began to learn about viruses.

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