Repairing A Home Injection Molding Machine

August 5, 2023 by Maya Posch 10 Comments

When [Michael] over at the Teaching Tech YouTube channel bought a hobby injection molding machine a long time ago, one of the plans he had with it was to use it for grinding up waste bits of PLA filament for injection molding. Since the machine was bought from a US shop and [Michael] is based in Australia it required some modifications to adapt it to the local 220+ VAC mains, followed by adding a PID temperature controller and a small compressor to provide the compressed air rather than from a large shop compressor.

Although [Michael] had discussed using the machine for PLA with the seller to confirm that this would work, a user error meant that the now defective unit had been sitting idly for many years, until recently.

Since the machine had been gathering dust and rust in the garage, fixing the machine up took a complete teardown to remove corrosion and resolve other issues. After this the original fault was identified, which turned out to be a shorted wire near the heater which had been turned up to a too high temperature, leading to the release of magic smoke and banishment of the machine to the Pit of Despair, AKA the shadowy depths of one’s garage.

In this first installment, [Michael] cleaned up the machine and restored it to a working state. In the next part injection molding will be attempted again, which should give some idea of the feasibility of turning scraps of PLA and failed 3D prints into smooth injection molded parts, assuming you have the CNC machine or patience to carve out the requisite molds, of course.

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The Simplest Curve Tracer Ever

August 2, 2023 by Dan Maloney 15 Comments

To a lot of us, curve tracing seems to be one of those black magic things that only the true wizards understand. But as [DiodeGoneWild] explains, curve tracing really isn’t all that complicated, and it doesn’t even require specialized test instruments — just a transformer, a couple of resistors, and pretty much whatever oscilloscope you can lay your hands on.

True to his handle, [DiodeGoneWild] concentrates on the current-voltage curves of Zener diodes in the video below, mainly as a follow-up to his recent simple linear power supply project, where he took a careful look at thermal drift to select the best Zener for the job. His curve tracer is super simple — just the device under test in series with a bunch of 10-ohm resistors and the secondary winding of a 12-volt transformer. The probes of his oscilloscope — a no-frills analog model — go across the DUT and the resistor, and with the scope in X-Y mode, the familiar current-voltage curve appears. Sure, the trace is reversed, but it still provides a good visualization of what’s going on. The technique also works on digital scopes; just be ready for a lot of twiddling to get into X-Y mode and to get the trace aligned.

Of course it’s not just diodes that can be tested with a curve tracer, and [DiodeGoneWild] showed a bunch of other two-lead components on his setup. But for our money, the neatest trick here was using a shorted bridge rectifier to generate a bright spot on the curve to mark the zero crossing point. Clever indeed, and pretty useful on a scope with no graticule.

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Open-Source Firmware For Soldering Irons

August 2, 2023 by Bryan Cockfield 23 Comments

For most of us, the first soldering iron we pick up to start working on electronics has essentially no features at all. Being little more than resistive heaters plugged straight into the wall with perhaps a changeable tip, there’s not really even a need for a power switch. But doing anything more specialized than through-hole PCB construction often requires a soldering iron with a little more finesse, though. Plenty of “smart” soldering irons are available for specialized soldering needs now, and some are supported by the open-source IronOS as well.

The project, formerly known as TS100, is a versatile soldering iron control firmware that started as an alternative firmware for only the TS100 soldering iron. It has since expanded to have compatibility with several other soldering irons and hosts a rich set of features, including temperature control, motion activation, and the ability to temporarily increase the temperature when using the iron. The firmware is also capable of working with irons that use batteries as well as irons that use USB power delivery.

For anyone with a modern smart soldering iron, like the Pinecil or various Miniware iron offerings, this firmware is a great way of being able to gain fine control over the behavior of one’s own soldering iron, potentially above and beyond what the OEM firmware can do. If you’re still using nothing more than a 30W soldering iron that just has a wall plug, take a look at a review we did for the TS100 iron a few years ago to see what you’re missing out on.

Photo via Wikimedia Commons

Pixel Pump, The Open Source Vacuum Pickup Tool Is Now Shipping

August 1, 2023 by Donald Papp 9 Comments

The Pixel Pump is an open source manual pick & place assist tool by [Robin Reiter], and after a long road to completion, it’s ready to ship. We first saw the Pixel Pump project as an entry to the 2021 Hackaday Prize and liked the clean design and the concept of a completely open architecture for a tool that is so valuable to desktop assembly. It’s not easy getting hardware off the ground, but it’s now over the finish line and nearly everything — from assembly to packaging — has been done in-house.

Pixel Pump with SMD-Magazines, also using foot pedal to control an interactive bill of materials (BoM) plugin.

Because having parts organized and available is every bit as important as the tool itself, a useful-looking companion item for the Pixel Pump is the SMD-Magazine. This is a container for parts that come on SMD tape rolls. These hold components at an optimal angle for use with the pickup tool, and can be fixed together on a rail to create project-specific part groups.

A tool being open source means giving folks a way to modify or add features for better workflows, and an example of this is [Robin]’s suggestion of using a foot pedal for hands-free control of the interactive BoM plugin. With it, one can simply use a foot pedal to step through a highlighted list of every part for a design, an invaluable visual aid when doing hand assembly.

The Pixel Pump looks great, but if you’d prefer to go the DIY route for vacuum pickup tools you would certainly be in good company. We’ve seen economical systems built for under $100, and systems built around leveraging bead-handling tools intended for hobbyists. On the extreme end there’s the minimalist approach of building a tool directly around a small electric vacuum pump.

Mechanical Pencil Solder Feeder Hack

July 29, 2023 by Chris Lott 29 Comments

Want a better way to feed solder, but want to do it on the quick and cheap? Well [ptkrf] has a solution for you in an old instructables post we stumbled upon recently. You might have, or can inexpensively buy, a mechanical pencil which has the feeder button on the side rather than on top, as usual. With the pencil in hand, [ptkrf] shows you the simple procedure for modifying the pencil into a solder feeder. You might need to experiment with different size pencils and solders to get a perfect match. Common mechanical pencils come in sizes to accommodate 0.5, 0.7, and 0.9 mm leads, but there are bigger and smaller ones available. Perhaps one of those really large drafting lead holders could be repurposed as a solder dispenser for the bigger jobs.

We discussed a 3D printed solder feeder a few days ago, but if you don’t have one, this may be a good way to go. Thanks to [iliis] for sending in this tip.

The Right Equipment Makes A Difference For Digital Oscilloscope Music

July 29, 2023 by Dan Maloney 4 Comments

We all love our cheap digital oscilloscopes, and with good reason. But if there’s one place where analog scopes still shine, it’s anywhere you need X-Y mode. Digitally sampling the inputs and mapping them on the screen as discrete points just isn’t the same as steering an electron beam around a CRT, making X-Y mode work on digital scopes — at least the affordable ones — somewhat lacking.

Thankfully, nobody told [Mark Hughes] that his digital scope would make a lousy X-Y display, so he just plunged ahead and figured out how to make it work anyway. The results are actually pretty good, but it took some doing. His setup begins with OsciStudio, an application built to take 3D shapes and animations and turn them into oscilloscope music. The output from that is piped to a USB sound card; [Mark] used a PreSonus Studio 26c, an adapter with DC-coupled inputs, which he found to be critical to getting good images. Also important was a USB isolator and good-quality cables, which greatly reduced jitter and made the image much more stable.

DC-coupled

AC-coupled

Displaying the image was as easy as connecting the left and right outputs from the sound card to the two scope inputs — [Mark] used a Keysight EDUX1052G — and setting it to X-Y mode. It took a fair amount of fiddling to get as far as he did, but we think the results speak for themselves. As for the sounds made by these images, he says it’s a bit like a hung sound card when a computer blue-screens. So, yeah — not exactly musical, but still an interesting way to have some fun with your digital scope.

A Simple One-Handed Solder Feeder

July 27, 2023 by Lewin Day 46 Comments

Soldering can get frustrating when you’re working fast. It often feels like you don’t have enough hands, particularly on jobs where you need to keep feeding solder in a hurry. To solve that issue, [mulcmu] developed a simple one-handed solder feeder.

The solder is fed out of the tip by simply dragging it with the thumb.

The intended use-case is for busy work like soldering long pin headers. The one-handed device allows solder to be continually fed while the other hand uses the soldering iron. It solves a long-running problem for [mulcmu], after their experiments with techniques inspired by TIG welding came to nought.

The design uses a pen-like form factor. A 3D-printed hollow tube has a wire ferrule inserted in the end, which serves as the tip of the device through which solder is fed. The tube has a cutaway, which allows the user to feed solder through using an easy motion of the thumb. The solder itself is fed from a spool in a regular bench top holder. If more slack is required in the solder feed, one simply pins the solder down in the device and tugs to draw more out.

If you find yourself regularly soldering repetitive jobs by hand, this could be a gamechanger for you. Those working in through-hole would be perhaps best served by this device. Meanwhile, if you’ve got nifty tool hacks of your own to share, don’t hesitate to let us know!