A closeup picture showing the jagged edge of the cut

Debugging Laser Cut Wobble, The Scientific Way

December 29, 2022 by Arya Voronova 23 Comments

[PWalsh] was using his lasercutter to cut acrylic, expecting the cuts to have a pleasantly smooth edge. Alas, the edges turned out to be wobbly and sandpaper-like, not smooth in the slightnest. Bummer! Internet suggested a stepper motor swap, but not much in the way of insights – and that would’ve been a royal pain for sure. How would you approach debugging such a problem? Well, [PWalsh] didn’t want to swap crucial components willy-nilly, going the scientific way instead, and breaks it down for us.

Having compiled an extensive list of possible places to look for a fault in, he started going through fundamental assumptions. Do other lasercutters experience this issue? No, even the cheap ones can cut things properly. Is it water level causing intermittent cooling? Nope, not that. Is it the stepping settings? Tweaked, not that. Laser pulsing frequency? No dice. Continue reading “Debugging Laser Cut Wobble, The Scientific Way” →

Reverse Engineering Saves Weller With A Wonky LCD From The Trash Pile

December 25, 2022 by Dan Maloney 15 Comments

There’s nothing more satisfying than finding a broken piece of gear in the trash and bringing it back to life. Satisfying, but also potentially more time-consuming — someone tossed it for a reason, after all. Figuring out what that reason is and finding a way to back it better is where the fun — and the peril — are.

Luckily, some pieces of equipment have a relatively short list of well-known failure modes, a fact that [Lauri Pirttiaho] relied on for this fix of an old Weller WD1 soldering station. The unit, sporting the familiar light blue Weller livery and more than a few scratches and dings, had an LCD that was DOA. Typically it’s the driver that’s the problem here, but [Lauri]’s diagnosis revealed it was the LCD module itself that was bad.

With OEM replacements being basically unobtainium at this point, the fix was to intercept the data heading from the driver to the old LCD and send it to a new, easily sourced 16×2 character LCD display. This began with an inspection of the display controller’s datasheet, and a bit of probing of the old display to find out which segments and backplanes map to which pins. A little bit of case modding allowed the new display to fit, the old controller chip was removed, and a PIC16 went into its place, in a tidy nest of Kapton tape and bodge wires. The PIC does the job of translating the original display, which had a fair number of custom icons and symbols, into sensible text-based equivalents and sending them to the 16×2 via I2C. The video below shows the hack in action; it honestly looks like it could have come from the factory like that.

The nice thing here is that [Lauri]’s fix applies to a whole range of Weller stations, so if you find one in the trash, you might be able to resuscitate it. Failing that, you could always roll your own Weller from (more-or-less) scratch.

Continue reading “Reverse Engineering Saves Weller With A Wonky LCD From The Trash Pile” →

Self-Propelled Chainsaw Reduces Injuries

December 25, 2022 by Bryan Cockfield 30 Comments

[Advoko] is an expert at milling logs into various sizes of boards. He typically uses nothing but a chainsaw to enable him to mill on-site without needing to bring any large or expensive equipment. The only problem is that sometimes he gets a little carried away running his mill non-stop until he has enough lumber for whatever project he is building, which has led to some repetitive strain injuries. To enable him to continue to run his mill, he’s created this self-propelled chainsaw jig.

The creation of the self-propelled chainsaw was a little serendipitous. [Advoko] needed to mill a tree which had fallen on a slope, and he couldn’t move the large trunk before starting to mill. To avoid fatigue while pulling his chainsaw upwards, he devised a system of rubber belts that would help pull the weight of the chainsaw up the hill. Noticing that if the chainsaw could have been operated downhill, it would essentially pull itself along the cut, he set about building a carriage for the mill to hold the chainsaw in place while it semi-autonomously milled lumber for him.

The chainsaw jig isn’t fully autonomous; [Advoko] still needs to start and stop the chainsaw and set up the jig. It does have a number of safety features to prevent damage to the jig, the chainsaw, and himself too, and over a number of iterations of this device he has perfected it to the point where he can start it on a cut and then do other tasks such as move boards or set up other logs for cutting while it is running, saving him both time and reducing his risk of other repetitive strain injuries. If you don’t fully trust the automatic chainsaw jig, take a look at this one which requires a little more human effort but still significantly reduces the strain of milling a large log.

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Laser Scanning Microscope Built With Blu-ray Parts

December 23, 2022 by Lewin Day 14 Comments

Laser scanning microscopes are useful for all kinds of tiny investigations. As it turns out, you can build one using parts salvaged from a Blu-ray player, as demonstrated by [Doctor Volt].

The trick is repurposing the optical pickup unit that is typically used to read optical discs. In particular, the build relies on the photodiodes that are usually used to compute focus error when tracking a disc. To turn this into a laser scanning microscope, the optical pickup is fitted to a 3D printed assembly that can slew it linearly for imaging purposes.

Meanwhile, the Blu-ray player’s hardware is repurposed to create a sample tray that slews on the orthogonal axis for full X-Y control. An ESP32 is then charged with running motion control and the laser. It also captures signals from the photodiodes and sends them to a computer for collation and display.

[Doctor Volt] demonstrates the microscope by imaging a small fabric fragment. The scanned area covers less than 1 mm x 1 mm, with a resolution of 127 x 127, though this could be improved with finer pitch on the slew mechanisms.

While it’s hardly what we’d call a beginner’s project, this technique still looks a lot more approachable than building your own scanning electron microscope.

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A Modern Tribute To The Classic HP-16C Calculator

December 21, 2022 by Lewin Day 19 Comments

The HP-16C Computer Scientist is much beloved as the only dedicated programmer’s calculator that Hewlett-Packard ever made. Most surviving examples in the world are well-used, and you haven’t been able to order one from HP since 1989. Thus, [K Johansen] set about building a tribute to the HP-16C using modern hardware.

The build relies on a Raspberry Pi Pico as the brains of the operation. As with so many classic HP calculators, it operates in Reverse Polish Notation, and includes the customary stack operations. To serve a programmer well, it’s set up to accept entry in hexadecimal, octal, decimal, and binary formats, and can readily convert between them. Beyond that, it’s equipped with the usual arithmetic operators, as well as bitwise operations like NOT, AND, and so on.

Perhaps what we love most, though, is the keypad. It was all put together with a combination of cheap AliExpress keypads, a label maker, and a laser printer. It’s a wholly DIY job, and a little rough around the edges, but it makes the calculator far easier to use.

It’s not an exact replica of the HP-16C, but the differences in operation are minor.Those wishing to build their own can grab the required files from the project’s Github page. We’ve seen replicas of other classic HP calculators before, too. If you’ve got your own mathematical projects brewing up in the lab, don’t hesitate to send them in to the tipsline!

Sliding Wrench Leaves A Little To Be Desired

December 21, 2022 by Al Williams 29 Comments

[Ben Conrad] received an interesting tool as a gift that purported to be a better mousetrap. It was a crescent wrench (made by the Crescent company, even) that didn’t have a tiny adjusting wheel like a traditional wrench. Instead, it had a slide running down the length of the handle. The idea is that you would push the slide to snug the wrench jaws against the bolt or nut, and that would be fast and easy compared to a conventional wrench. As [Ben] notes, though, it doesn’t work very well. Most of us would have just dumped it in the back of the tool chest or regifted it. [Ben] tore his apart to find out what was wrong with it.

A typical adjustable wrench has four parts. This one has 19 parts and looks like a conventional wrench with an extra slide and screw running down the length of the handle. [Ben] found the parts were poorly made, but that wasn’t the main problem.

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3D Printed Gadgets Make Lab Work Easier

December 15, 2022 by Lewin Day 1 Comment

If you’ve worked in a bio or chem lab, you’ve probably found yourself handling all manner of plastic. Test tubes, fixtures, clamps — there’s a cavalcade of this stuff that fattens up the order books of lab suppliers every quarter. Sometimes, though, the commercial solutions aren’t quite what you need. For [AtomicVirology], the solution was to 3D print custom lab accessories to make work easier.

The tube adapter allows the collection of 60 small samples without having to unload the fraction collector halfway through. That’s a big quality-of-life improvement for staffers using the equipment.

Some of the devices are straightforward, like simple holders for upright storage of centrifuge tubes. Others are fun twists on the theme, like the Millennium Falcon tube holder or one shaped like the Imperial Star Destroyer. Meanwhile, a resuable plastic tube cover serves as a way to protect tubes from light without the fuss of covering them in aluminium foil. It’s less wasteful, too!

Our favorite, though, is a simple adapter for holding fraction tubes in a AKTA fraction collection device. Stock, the AKTA device will hold 30 small tubes in the inside ring, and 30 larger tubes in the outside ring. Thanks to a simple printed part, though, it can be modified to hold 60 tubes of the smaller size. This allows the collection of 60 small fractions in a shorter period of time simply by moving the delivery head from the inner to the outer ring, without having to swap out 30 tubes halfway through a chromatography column, for example.

It goes to show that a 3D printer is good for more than just churning out Pikachus. It’s a Swiss Army knife for solving fiddly little problems without having to rely on some company to injection-mold you 10,000 examples of whatever it is you want. Of course, if you do want to injection mold something, we’ve covered how to do that before, as well.