A large silver cone attached to a black hemisphere floats over a piece of sheet metal held in a metal frame. The metal has what appears to be machine grease on it to aid in the forming process.

CNC Metal Forming

October 18, 2024 by Navarre Bartz 30 Comments

Forming complex shapes in metal sheets is still a laborious process, especially if you aren’t needing more than a couple parts so stamping doesn’t make sense. That may change with Digital Sheet Forming.

While this video is basically an ad for one vendor’s approach, it gives a good set of examples of what the technique can achieve. The high pressure mechanism of the machine presses the metal layer by layer down against a silicone backing to form what you’ve designed, in this case, the nose cone for a Tucker Carioca.

Some people will decry it killing the metal forming industry, but as [Rob Ida] says in the video, it will allow metal formers to become more efficient at the work they do by taking out the tedium and letting them focus on the parts of the process requiring the most skill. Anyone who’s done any work with a 3D printer or CNC mill will know that sending a file to a machine is only one small part of the process.

We’re anxious to see this technology make its way to the makerspace and home shop. If you want to do some sheet metal forming now, why not try hydroforming?

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The FNIRSI HRM-10 Internal Resistance Meter

October 17, 2024 by Dave Rowntree 14 Comments

Occasionally, we find fun new electronic instruments in the wild and can’t resist sharing them with our readers. The item in question is the FNIRSI HRM-10 Internal resistance meter, which we show here being reviewed by [JohnAudioTech].

So what does it do, and why would you want one? The device is designed to measure batteries so you can quickly determine their health. Its operating principle also allows it to do a decent job of measuring low-resistance parts, which is not necessarily as easy to achieve with the garden variety multimeter, especially the low-end ones. We reckon it would be useful in the field for checking the resistance of switches and relays, possibly in automotive or industrial applications. The four-pin connector is needed because there are two wires per probe, making a Kelvin (also known as four-wire) connection.

Likely, the operating principle is to apply a varying load to the battery under test and then measure the voltage drop. The slope of the voltage sag vs load is a reasonable estimate of the resistance of the source, at least for the applied voltage range. The Kelvin connection uses one pair of wires to apply the test current from a relatively low-impedance source and the second pair to measure the voltage with a high input impedance. That way, the resistance of the probe wires can be calibrated out, giving a much more accurate measurement. Many lab-grade measurement equipment works this way.

Circling back to the HRM-10, [John] notes that it also supports limit testing, making it a helpful gauging tool for the workbench when sorting through many batteries. Data logging and the ability to upload to a computer completes the feature set, which is quite typical for this level of product now. Gone are the days of keeping a manual logbook next to the instrument stack and writing everything down by hand!

We’ve touched on measuring battery internal resistance before, but it was a while ago. Regarding Kelvin connections, here’s a quick guide and a hack upgrading a cheap LCR to support 4-wire probes.

Continue reading “The FNIRSI HRM-10 Internal Resistance Meter” →

Solve: An ESP32-Based Equation Solving Calculator

October 15, 2024 by Dave Rowntree 10 Comments

We’re suckers for good-looking old-school calculators, so this interesting numerical equation-solving calculator by [Peter Balch] caught our attention. Based around the ESP32-WROOM-32 module and an LCD, the build is quite straightforward from an electronics point of view, with the main work being on the software side of things.

A custom keyboard was constructed on Veroboard using a handful of tactile switches arranged in a charlieplexing array to minimize the number of IO pins consumed. For the display, an off-the-shelf 240×320 ILI9341-based module hooked up by SPI was used. A single lithium cell was used for the power supply, connected to a USB

You don’t need much to make a usable keyboard.

charger module, but you could just as easily substitute a 3 x AA battery box. The case was designed in DesignSpark mechanical and 3D printed. It’s unclear what keyboard version they settled on; there are options for one with keycaps and one without. Regardless, a 3D-printed frame sits atop the keyboard circuit, with the graphics printed on photo paper and a protective coversheet on top. Continue reading “Solve: An ESP32-Based Equation Solving Calculator” →

A Power Supply With Ultra High Resolution Current Measurement Built In

October 10, 2024 by Lewin Day 11 Comments

Need to do some real fine power consumption measurements? [Gero Müller] was in that exact situation, and wasn’t happy with the expensive off-the-shelf tools for doing the job. Thus, he built his own. Meet nanoTracer.

*nanoTracer measures small current draws in very high resolution.*

The concept of the device is simple. It’s a power supply that measures current on a nanoampere scale, and on microsecond intervals. It can deliver from 0 to 5.125 volts in 256 steps, and up to 100 mA of current. It has a sampling bandwidth of 1 MHz, at 2 million samples per second, with effective dynamic range from 100 mA all the way down to 100 nA. For capturing microscopic changes in current draw, that’s invaluable. The device also features a UART for talking to an attached project directly, and additional pins for taking further ADC measurements where needed.

Right now, it’s at an early prototype stage, and [Gero] tells us the software is “very basic” right now. Still, it’s easy to see how this device would be very useful to anyone working to optimize power consumption on low-power projects. One wonders if there are some applications in power-based side-channel attacks, too.

We’re hoping to learn more about nanoTracer from [Gero] soon—how it was built, how it works, and what it’s really like to use. Perhaps one day down the line, the design might even become available for others that could use such a nifty tool. There’s no mucking about when you get down to nanoamps, after all. If you’ve cooked up something similar in your own lab, don’t hesitate to let us know!

Building A 3D Printed Scanning Tunneling Microscope

September 30, 2024 by Dave Rowntree 12 Comments

YouTuber [MechnicalRedPanda] has recreated a DIY STM hack we covered about ten years ago, updating it to be primarily 3D-printed, using modern electronics, making it much more accessible to many folks. This simple STM setup utilises a piezoelectric actuator constructed by deliberately cutting a piezo speaker into four quadrants. With individual drive wires attached to the four quadrants. [MechPanda] (re)discovered that piezoelectric ceramic materials are not big fans of soldering heat. Still, in the absence of ultrasonic welding equipment, he did manage to get some wires to take to the surface using low-temperature solder paste.

As you can tell, you can only image conductive samples

A makeshift probe holder was glued on the rear side of the speaker actuator, which was intended to take a super sharp needle-like piece of tungsten wire. Putting the wire in tension and cutting at a sharp angle makes it possible with many attempts to get some usable points. Usable, in this instance, means sharp down the atomic level. The sample platform, actuator mount and all the connecting parts are 3D-printed with PA-CF. This is necessary to achieve enough mechanical stability with normal room temperature fluctuations. Three precision screws are used to level the two platforms in a typical kinematic mount structure, which looks like the only hard-to-source component. A geared stepper motor attached to the probe platform is set up to allow the probe to be carefully advanced towards the sample surface. Continue reading “Building A 3D Printed Scanning Tunneling Microscope” →

Internet Connected TI-84 To Cut Your Academic Career Short

September 29, 2024 by Danie Conradie 22 Comments

In an educational project with ethically questionable applications, [ChromaLock] has converted the ubiquitous TI-84 calculator into the ultimate cheating device.

The foundation of this hack lies in the TI-84’s link protocol, which has been a mainstay in calculator mods for years. [ChromaLock] uses this interface to connect to a tiny WiFi-enabled XIAO ESP32-C3 module hidden in the calculator. It’s mounted on a custom PCB with a simple MOSFET-based level shifting circuit, and slots neatly into a space on the calculator rear cover. The connecting wires are soldered directly to the pads of the 2.5 mm jack, and to the battery connections for power.

But what does this mod do? It connects your calculator to the internet and gives you a launcher with several applets. These allow you to view images badly pixelated images on the TI-84’s screen, text-chat with an accomplice, install more apps or notes, or hit up ChatGPT for some potentially hallucinated answers. Inputting long sections of text on the calculator’s keypad is a time-consuming process, so [ChromaLock] teased a camera integration, which will probably make use of newer LLMs image input capabilities. The ESP32 doesn’t handle all the heavy lifting, and needs to connect to an external server for more complex interfaces.

To prevent pre-installed programs from being used for cheating on TI-84s, examiners will often wipe the memory or put it into test mode. This mod can circumvent both. Pre-installed programs are not required on the calculator to interface with the hardware module, and installing the launcher is done by sending two variables containing a password and download command to the ESP32 module. The response from the module will also automatically break the calculator out of test mode.

We cannot help but admire [ChromaLock]’s ingenuity and polished implementation, and hopefully our readers are more interested in technical details than academic self-sabotage. For those who need even more capability in their calculator, we’d suggest checking out the NumWorks. Continue reading “Internet Connected TI-84 To Cut Your Academic Career Short” →

Spectroscopy On The Cheap

September 27, 2024 by Al Williams 11 Comments

[Project 326] wanted to know exactly what gas was in some glass tubes. The answer, of course, is to use a spectrometer, but that’s an expensive piece of gear, right? Not really. Sure, these cheap devices aren’t perfect, but they are serviceable and, as the video below shows, there are ways to work around some of the limitations.

The two units in question are “The Little Garden” spectrometer and a TLM-2. Neither are especially sensitive, but both are well under $100, so you can’t expect much. Because the spectrometers were not very sensitive, a 3D printed jig and lens were used to collect more light and block ambient light interference. The jigs also allowed the inclusion of special filters, which enhanced performance quite a bit. The neon bulbs give off the greatest glow when exposed to high voltage. Other bulbs contain things like helium, xenon, and carbon dioxide. There were also tubes with mercury vapor and even deuterium.

We’ll admit it. Not everyone needs a spectrometer, but if you do, there’s a lot of really interesting info on how to get the most out of these cheap devices. Apparently, [Project 326] was frustrated that he couldn’t buy an X-ray spectrometer and has vowed to create one, so we’ll be interested to see how that goes.

Some homebrew spectrometers can get pretty fancy. Of course, there’s more to spectroscopy than just optics.

Continue reading “Spectroscopy On The Cheap” →