Take A Mini Lathe For A Spin

December 31, 2018 by Brian McEvoy 24 Comments

[This Old Tony] is no stranger to quality tools, but he started on a mini lathe. Nostalgia does not stop him from broadcasting his usual brand of snark (actually, it is doubtful that anything short of YouTube going offline will stop that). He rates the lathe’s ability to machine different materials and lets you decide if this is an investment, or a money pit.

Lathe parts range from a chintzy start/stop button assembly that looks like it would be at home on a Power Wheels restoration project to a convenient cam locking mechanism on the tail stock which is an improvement on the lathe with which our narrator learned. We see the speed tested and promptly disproved as marketing hoopla unless you allow for a 40% margin of error. It uses a 500 watt DC motor, so don’t try correcting for mains power frequency differences. The verdict on the lead screw and thread dial is that you get what you pay for and this is demonstrated by painstakingly cutting threads into aluminum. Finally, we see torture tests on cold rolled steel.

Maybe someone from the mini lathe community will stop by with their two-cents. If you appreciate this introduction to lathes, consider [This Old Tony]’s guide to CNC machines or injection molding. But for us, [Quinn Dunki’s] series of machine tools has been a real treat this year.

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Printed It: Parametric Hex Key Holder

December 27, 2018 by Tom Nardi 22 Comments

Desktop 3D printing is an incredible technology to be sure, but it’s not a cure-all. If you’re interested in making something in large numbers, or if production speed is a concern, 3D printing probably isn’t what you’re looking for. But on the flip side, if you want to make a few highly specialized or customized objects, desktop 3D printing represents an absolute revolution in capability for the individual hacker and maker.

In our ongoing mission to prove that desktop 3D printing isn’t just a novelty, we keep a close eye out for printable objects which play to the strengths of the technology. You won’t find any benchmarks or dust collectors here; everything featured in Printed It is a bona fide practical object. An ideal entry into this series is something that you wouldn’t need to print more than a few times, isn’t easily sourced or made via traditional means, and if possible, offers some form of customization which makes it more suitable to the individual’s needs than what’s commercially available.

Not every object we feature hits all of these marks, but this parametric hex key holder designed by [Daniel Leitner] absolutely does. This object was created to address a problem that we imagine most Hackaday readers share: taming an ever-growing collection of hex keys. What’s more, this design is something of an open source success story. It’s an idea that passed through the hands of multiple community members, becoming more refined and functional as it went. Even if you don’t personally need to wrangle some unruly hex keys, this object is a fascinating look at how 3D printing and the community that has sprouted up around it is truly evolving the process of going from concept to execution.

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Clever Wedges That Will Increase Your PCB Assembly Yield

December 22, 2018 by Brian Benchoff 22 Comments

If there’s one thing that will bring down the yield of your PCB assembly, it’s your solder paste. Put too much on, and you’ll get bridged leads. If you don’t put enough on, that pad might not make good contact. [ScalarElectric] has an amazing trick that’s sure to astonish and astound. Just use wedges and you’ll get better yield with fine-pitched components.

The trick here is to define the cream/solder paste layer of each package as a wedge on each pad instead of the usual rectangle. This gives a few benefits, the largest being the increased gap between paste shapes. You’re also getting a reduction in the total amount of paste applied, and a subsequent improvement in yield. (Reportedly, we’d love to see some data on this.)

PCB design tools usually have a way to alter the size of the cream/solder paste layer of a design, and indeed one option is to simply shrink the size of the paste layer elements. The trick to the wedges is increasing the total distance between solderpaste blobs while keeping the total amount of solderpaste high. This technique can be used down to 0.5mm pitch parts, and everything works like a charm.

While this is a little outside of our wheelhouse here at Hackaday — it is, after all, a novel use of existing tools that is mostly applicable to electronic design and production. [Ed Note: Sarcasm.] You can check out a few pics of this technique in the slideshow below. If you test this technique out, be sure to let us know how it went!

Manual 3D Digitizer Works A Bit Like 3-Dimensional Measuring Tape

December 21, 2018 by Donald Papp 26 Comments

Digitizing an object usually means firing up a CAD program and keeping the calipers handy, or using a 3D scanner to create a point cloud representing an object’s surfaces. [Dzl] took an entirely different approach with his DIY manual 3D digitizer, a laser-cut and 3D printed assembly that uses rotary encoders to create a turntable with an articulated “probe arm” attached.

Each joint of the arm is also an encoder, and by reading the encoder values and applying a bit of trigonometry, the relative position of the arm’s tip can be known at all times. Manually moving the tip of the arm from point to point on an object therefore creates measurements of that object. [Dzl] successfully created a prototype to test the idea, and the project files are available on GitHub.

We remember the earlier version of this project and it’s great to see how it’s been updated with improvements like the addition of a turntable with an encoder. DIY 3D digitizing takes all kinds of approaches, and one example was this unit that used four Raspberry Pi Zeros and four cameras to generate high quality 3D scans.

Woodworker Goes From 3D-Printing Skeptic To Believer

December 20, 2018 by Dan Maloney 30 Comments

If there’s one place where the old ways of doing things live a longer life than you’d otherwise expect, it’s the woodshop. Woodworkers have a way of stubbornly sticking to tradition, and that usually works out fine. But what does it take to change a woodworker’s mind about a tool that seems to have little role in the woodshop: the 3D-printer?

That’s the question [Marius Hornberger] asked himself, and at least for him, there are a lot of woodworking gadgets that can be 3D-printed. [Marius] began his journey into additive manufacturing three years ago as a skeptic, not seeing how [Benchy] and friends could be of any value to his endeavors. But as is often the case with a tool that can build almost anything, all it takes is a little ingenuity to get started. His first tool was a pair of soft jaws for his bench vise. This was followed by a flood of useful doodads, including a clever center finder for round and square stock, custom panels for electrical switches, and light-duty pulleys for some of the machines he likes to build. But [Marius] obviously has an issue with dust, because most of his accessories have to do with helping control it in the shop. The real gem of this group is the hose clamp for spiral-reinforced vacuum hose; standard band clamps don’t fit well on those, but his clamps have an offset that straddles the wire for a neat fit. Genius!

[Marius] has kindly made all his models available on Thingiverse, so feel free to dig in and start kitting out your shop. Once you do maybe you can start building cool things like his all-wood scissors lift.

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Rigol MSO5000 Hacked, Features Unlocked

December 19, 2018 by Eric Evenchick 103 Comments

Rigol’s test gear has something of a history of being hacked. Years ago the DS1022C oscillocope was hacked to increase bandwidth, and more recently the DS1054Z was hacked to unlock licensed features. Now, it’s the MSO5000’s turn.

Over on the EEVBlog forums a group has been working on hacking another Rigol, the MSO5000, a 70 MHz oscilloscope which can be upgraded to 350 MHz via software licensing. Various other features including a two channel, 25 MHz arbitrary waveform generator are also built-in, but locked out unless a license key is purchased. The group have managed to enable all the locked options without license keys.

The hack is quite simple. The Linux system running on the scope has a default root password of, you guessed it, “root”. After logging in over SSH with these credentials, the user just needs to modify the startup file to add the “-fullopt” flag to the “appEntry” application. This starts the application in a fully unlocked state, which gives access to all the features.

The MSO5000 costs about $1000, and the bandwidth option alone adds over $3000 to the price. If you’re willing to risk your warranty, and you have the skills to edit a file with vi, this hack provides a serious upgrade for free.

If you have a DS1022C you’ll find our reporting on its hack here, and likewise DS1054Z owners will find theirs here.

Header image: EEVBlog.

Scott Swaaley On High Voltage

December 14, 2018 by Jenny List 29 Comments

If you were to invent a time machine and transport a typical hardware hacker of the 1970s into 2018 and sit them at a bench alongside their modern counterpart, you’d expect them to be faced with a pile of new things, novel experiences, and exciting possibilities. The Internet for all, desktop computing fulfilling its potential, cheap single-board computers, even ubiquitous surface-mount components.

What you might not expect though is that the 2018 hacker might discover a whole field of equivalent unfamiliarity while being very relevant from their grizzled guest. It’s something Scott Swaaley touches upon in his Superconference talk: “Lessons Learned in Designing High Power Line Voltage Circuits” in which he describes his quest for an electronic motor brake, and how his experiences had left him with a gap in his knowledge when it came to working with AC mains voltage.

When Did You Last Handle AC Line voltages?

If you think about it, the AC supply has become something we rarely encounter for several reasons. Our 1970s hacker would have been used to wiring in mains transformers, to repairing tube-driven equipment or CRT televisions with live chassis’, and to working with lighting that was almost exclusively provided by mains-driven incandescent bulbs. A common project of the day would have been a lighting dimmer with a triac, by contrast we work in a world of microcontroller-PWM-driven LEDs and off-the-shelf switch-mode power supplies in which we have no need to see the high voltages. It may be no bad thing that we are rarely exposed to high-voltage risk, but along the way we may have lost a part of our collective skillset.

Scott’s path to gaining his mains voltage experience started in a school workshop, with a bandsaw. Inertia in the saw kept the blade moving after the power had been withdrawn, and while that might be something many of us are used to it was inappropriate in that setting as kids are better remaining attached to their fingers. He looked at brakes and electrical loads as the solution to stopping the motor, but finally settled on something far simpler. An induction motor can be stopped very quickly indeed by applying a DC voltage to it, and his quest to achieve this led along the path of working with the AC supply. Eventually he had a working prototype, which he further developed to become the MakeSafe power tool brake.

Get Your AC Switching Right First Time

The full talk is embedded below the break, and gives a very good introduction to the topic of switching AC power. If you’ve never encountered a thryristor, a triac, or even a diac, these once-ubiquitous components make an entrance. We learn about relays and contactors, and how back EMF can destroy them, and about the different strategies to protect them. Our 1970s hacker would recognise some of these, but even here there are components that have reached the market since their time that they would probably give anything to have. We see the genesis of the MakeSafe brake as a panel with a bunch of relays and an electronic fan controller with a rectifier to produce the DC, and we hear about adequate safety precautions. This is music to our ears, as it’s a subject we’ve touched on before both in terms of handling mains on your bench and inside live equipment.

So if you’ve never dealt with AC line voltages, give this talk a look. The days of wiring up transformers to power projects might be largely behind us, but the skills and principles contained within it are still valid.

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