DIY Automated Printer Kerchunks Out Classic Embossed Labels

June 15, 2022 by Dan Maloney 27 Comments

For our money, the best label for pretty much any purpose is one of those embossed Dymo-style stick-on labels, the kind with the raised white letters. There’s just something about them — the raised letters just beg to be touched, their legibility is outstanding, they lend an unmatched retro feel to a project, and the experience of creating one with one of those manual kerchunkers is oddly satisfying.

But alas, those manual label makers aren’t what they used to be, as [Andrei Speridião] discovered when his fell apart in his hands. Rather than complain, he automated his label maker and turned it into a computer peripheral. Dubbed “E-TKT”, the DIY label printer takes the daisy-wheel embossing die from his defunct labeler and puts it under computer control. Rather than the ratchet mechanism of the original, a stepper motor advances the tape, another stepper rotates the wheel to the correct position, and a servo does the kerchunking duty. The process repeats until the label is complete and neatly cut off, ready to apply. An ESP32 runs the mechanism and serves up a web application to compose labels and control the printer. There’s also an OLED display and, of course, an embossed label. Video demo below.

We don’t care what [Bart Simpson] thinks, embossed labels are cool, and this makes them even cooler. And as [Andrei] points out, this is also a neat way around the nasty DRM trick that some companies are foisting on the label-making public. That alone is reason to cheer this project on — but we won’t complain about the beautiful photography and excellent documentation, either.

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2022 Hackaday Prize: Hack It Back And Make It Yours

June 13, 2022 by Tom Nardi 3 Comments

The 2022 Hackaday Prize continues to hurtle along, with two of the five Challenges already in the rear-view mirror. While we’re naturally excited about every phase of this year’s contest, we’ve got particularly high hopes for what the community can do with this third Challenge: Hack it Back.

It’s a simple formula: find some outdated and disused piece of gear, spruce it up, and keep it out of the landfill. But extending the lifetime of consumer hardware is only one side of the coin, by upgrading and modifying something instead of buying an off-the-shelf replacement, you also turn the mundane into something unique and personal. But of course, we hardly have to explain the benefits to you fine folk — this is the sort of bespoke engineering we see on a nearly daily basis here at Hackaday. The difference now is that there’s cash prizes on the line.

So if there’s an old iPod collecting dust in your desk, perhaps now is the time to replace its guts with some modern silicon and teach it a few new tricks. Sure a brand-new robotic vacuum might be nice, but you could save yourself some money by picking up a second-hand Roomba and tucking an ESP8266 onboard. Got a nice piece of test equipment that predates the handy data export functions we take for granted these days? You might need to use the nuclear option and skim the desired data right off the unit’s LCD controller. We could spend all day pulling examples from the archives, but you get the picture.

What’s that you say? You aren’t the type to be seduced by shiny new features? Happy to keep things local while others ship it all off to the cloud? You’ll get no complaints from us, and that’s why the Hack it Back Challenge also recognizes repairs that simply put a piece of gear back into service. But don’t be fooled, as fixing something can often be harder than rebuilding it from scratch.

When you’ve got to crack out the x-ray machine to find all the damaged traces on a decades-old PCB, only to then tediously replace them all with microscopic bits of wire, you may find yourself wondering what you’ve done to anger the Keeper of the Magic Smoke. On the other hand, plenty a gadget has been disabled due to nothing more exotic than a single bad solder joint. In either event, there’s a certain sense of satisfaction when you can return a literal piece of history to working condition.

Ready to put your hardware-reviving skills on display? Just head over to Hackaday.io, make a new project page, and get hacking. But don’t wait too long, you’ve only got until July 24th to enter the Hack it Back Challenge and stake your claim on one of the ten $500 awards up for grabs.

the dongle developed by Marcel, with a USB-A plug on one end and an SMD antenna on the other

Hackaday Prize 2022: House Ventilation Reverse-Engineered And Automated

June 1, 2022 by Arya Voronova 5 Comments

[Marcel] thought – what if he had more control over his house ventilation system? You could add some nifty features, such as automatically ventilating your house in the mornings when everyone’s away, only creating noise when nobody’s around to hear it. Sadly, most ventilation systems are not automation-friendly at all – he was lucky, however, as his system came with a wireless remote. [Marcel] reverse-engineered this remote, created a USB dongle speaking the same protocol, and tied it into his Home Assistant setup!

The remote in question is Orcon R15, with an Atmel MCU talking to a CC1101 chip through SPI. He sniffed the SPI communications when pressing different buttons, figured out the protocol by comparing the recordings, and built a test setup with a spare Arduino and CC1101 module. It worked, and he set out to design a separate dongle, using an ATMega32U4. The dongle looks pretty neat, and fits a Hammond enclosure – what’s not to like?

Then he set out to develop the firmware, and didn’t disappoint on that front either. His code doesn’t just imitate the original remote perfectly in terms of control, it also has user-friendly pairing flow, keeps track of the system’s current state, and still lets the original remote be used in parallel. Eagle files for the PCB are available on the project page, with the code and a PDF schematic available in the GitHub repo. This entire journey is described in the Hackaday.io page, and we would recommend you check it out for all the insights it provides!

Ventilation systems don’t tend to be designed for automation, and it’s endearing to see hackers working on conquering this frontier. Last time we’ve seen a ventilation system hack, it had the additional challenge of being landlord-friendly, and we think the hacker nailed it!

The new PewPew with an LCD showing some patterns, being held in someone's hand.

Hackaday Prize 2022: PewPew LCD Plays With Python

May 27, 2022 by Arya Voronova 4 Comments

[deshipu] aka [Radomir Dopieralski] has been building educational handhelds for a good part of a decade now, and knows how to design hardware that makes for effective teaching. Today, we are graced with the PewPew LCD project, latest in the PewPew student-friendly handheld series, powered by CircuitPython.

The goal for all of these devices has been consistent — making game programming accessible and fun. This time, as an entry in the Reuse, Recycle, Revamp round of Hackaday Prize, the new PewPew receives an upgrade – from an 8×8 LED matrix to an LCD display. This might not sound like much, but the change of display technology itself isn’t the main point. [deshipu] is working on ways to bring down the price and assembly complexity of PewPew handhelds, and he’s found there’s plenty of old stock RH-112 displays, previously used on cellphones like Nokia 1202, which these days go for as little as $1.30 a piece.

It’s exceptionally simple to get into writing games for the PewPew – one of the reasons why it’s a strong platform for workshops and individual learning. There’s already a slew of games and tutorials, and we can’t wait to see all the cool games people can build when given all the extra pixels! And, of course, we appreciate setting an example for giving new life to old displays – displays that’d otherwise inevitably end up in a trash container behind a warehouse in China.

The Reuse, Recycle, Revamp Hackaday Prize 2022 round is going on for two more weeks. If you’re making good use of something that would otherwise be discarded, please do share it with us, so that we can all learn and draw inspiration from your projects!

Hackaday Prize 2022: Upcycling Acrylic Scraps

May 25, 2022 by Bryan Cockfield 9 Comments

Living and working in a remote rain forest may sound idyllic to those currently stuck in bland suburbia, and to be sure it does have plenty of perks. One of the downsides, though, is getting new materials and equipment to that remote location. For that reason, [Digital Naturalism Laboratories], also known as [Dinalab], has to reuse or recycle as much as they can, including their scraps of acrylic leftover from their laser cutter.

The process might seem straightforward, but getting it to actually work and not burn the acrylic took more than a few tries. Acrylic isn’t as thermoplastic as other plastics so it is much harder to work with, and it took some refining of the process. But once the details were ironed out, essentially the acrylic scraps are gently heated between two steel plates (they use a sandwich press) and then squeezed with a jack until they stick back together in one cohesive sheet. The key to this process is to heat it and press it for a long time, typically a half hour or more.

With this process finally sorted, [Dinalab] can make much more use of their available resources thanks to recycling a material that most of us would end up tossing out. It also helps to keep waste out of the landfill that would otherwise exist in the environment indefinitely. And, if this seems familiar to you, it’s because this same lab has already perfected methods to recycle other types of plastic as well.

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Resulting tweezer assembly, with a 3D printed replacement case for both of the probes

Hackaday Prize 2022: Glue-Hindered Smart Tweezer Repair Involves A Rebuild

May 23, 2022 by Arya Voronova 1 Comment

[Dan Julio] owns a pair of Miniware multimeter tweezers, a nifty helper tool for all things SMD exploration. One day, he found them broken – unable to recognize any component between the two probes. He thought it could be a broken connection problem, and decided to take them apart. Presence of some screws on their case fooled him – in the end, it turned out that the case was glued together, and could only be opened destructively. For an entry in the “Reuse, Recycle, Revamp” round of 2022 Hackaday Prize, he tells us how he brought these tweezers back from the dead.

During the disassembly, he broke a custom flexible PCB, which wasn’t reassuring either. However, that was no reason to give up – he reverse-engineered the connections and the charging circuitry, then assembled parts of the broken tweezers together using a small generic protoboard as a base. Indeed, it was likely a broken connection between probes, because the reassembled tweezers worked!

Of course, having exposed PCBs wouldn’t do, and from the very start, assembling these tweezers back together was not an option. Instead, he developed a replacement case in OpenSCAD, bringing the tweezers back to life as his trusty tool – and still leaving repairability on the table. If you’re interested in the details, he goes more into how these tweezers are designed when it comes to charging and connectivity, and we recommend that you give his write-up a read!

We’ve been seeing smart tweezers around for over a decade now, from reviews and hacks of commercially made ones, to DIY chopstick-based and PCB-based ones. If you already own a pair of tweezers you’ve grown attached to, you can neatly retrofit them with a capacitance sensing function!

Hackaday Prize 2022: Recycled Tire Table Is Where The Rubber Meets The Road

May 18, 2022 by Kristina Panos 43 Comments

The problem with good inventions is that we usually end up with way too many of that particular widget lying around, which can cause all kinds of problems. Take the car tire, for instance. They were a great invention that helped spell the end of buggy whips and broken wagon wheels. But there are so many used-up tires about today that some people end up burning them in large piles, of all possible things.

Not [Vaibhav], who prefers to turn trash into utilitarian treasures. With little more than an old tire, some jute rope, and four plastic drink bottles, they made a sturdy, low-slung piece of furniture that could be used as a coffee table, a foot stool, or whatever life calls for.

Construction was fairly simple and involved stabilizing the hollow core with a round piece of cardboard glued to either side of the tire. Then came the jute rope and glue artistry, which hides any trace of the foundational materials. Finally, [Vaibhav] glued four plastic bottles to the bottom to act as legs. We think that steel cans would last longer and support more weight, but if plastic bottles are the only option, you could always fill them with dirt or sand.