Taking A Close Look At Hawkeye’s Workbench

December 30, 2021 by Tom Nardi 51 Comments

We don’t have to tell you that the representation hackers and makers get in popular media is usually pretty poor. At this point, we’ve all come to accept that Hollywood is only interested in perpetuating negative stereotypes about hackers. But in scenes where the plot calls for a character to be working on an electronic device, it often seems like the prop department just sticks a soldering iron in the actor’s hand and calls it a day.

Of course, there are some exceptions. In the final episode of Marvel’s Hawkeye, the titular character is shown building some custom gear in a work area that looks suspiciously like somewhere actual work might get done. The set design was impressive enough that [Giovanni Bernardo] decided to pause the show and try to identify some of the tools and gadgets that litter the character’s refreshingly chaotic bench.

Now to be clear, we haven’t personally seen the latest Marvel spectacle from the House of Mouse, and it’s entirely possible that the illusion falls apart when taken as a whole. But from what we’re seeing here, it certainly looks like whoever did the set dressing for Hawkeye seems to have made an effort to recreate the hackerspace chic. We’ve got a multimeter within arm’s reach, the classic magnifying glass third arm, a Wiha screwdriver about to roll out of frame, and even some JB-Weld. If this looks eerily like what’s currently on your own bench, don’t worry, you’re not alone.

On the wider shot, we can see that the attention to detail wasn’t limited to the close-up. From the tools hanging on the pegboard to the shelves filled with rows of neatly labeled bins, we totally buy this as a functional workspace. It’s quite a bit neater than where we currently do our tinkering, but that’s more of a personal problem than anything. As we’ve seen, there are certainly people in this community who take their organization seriously.

Portrayals of science or technology in the media often leave a lot to be desired, which is why it’s so important to praise productions that put in the effort to get things right. With a little luck, maybe it will get through to the right people and raise the bar a bit. But even if it doesn’t change anything, we can at least give the folks behind the scenes some well-deserved recognition.

Build Your Own High-Temp Oven Thermometer

December 29, 2021 by Tom Nardi 9 Comments

Looking to keep an eye on the temperature inside his wood-fired pizza oven, [Giovanni Bernardo] decided to skip the commercial offerings and build his own high-temperature thermometer using a type-K thermocouple. The end result is a no-nonsense handheld unit with a surprisingly low part count that, at least in theory, can read temperatures as high as 1023.75°C. Though we hope he’ll be pulling the pizza out long before that.

Inside the 3D printed case we find just a handful of components. The 0.91″ OLED display mounted in the front panel is wired to a Digispark ATtiny85 development board, which in turn is connected to a MAX6675 breakout board. This takes the input from the thermocouple probe and converts it into a digital signal that can be read over SPI with an Arduino library from Adafruit. Rather than going through the added complication of adding a rechargeable pack, [Giovanni] is running this thermometer from a standard 9 V battery thanks to the 5 V regulator built into the Digispark.

We especially appreciate the attention to detail [Giovanni] put into his case design. Each component is nestled into a perfectly formed pocket in the bottom of the box, and he’s even gone through the trouble of using heat-set inserts for the front panel screw holes. It would have been quicker and easier to just model up a basic box and hot glue his components in place, but he took the long way around and we respect that.

This project is another example of an interesting principle we’ve observed over the years. Put simply, if somebody is going through this much trouble to check an object’s temperature, there’s a higher than average chance they intend on eating it at some point.

Eric Strebel peeks through his Pfaff 463 industrial sewing machine.

Simple Upgrades Make An Old Industrial Sewing Machine New Again

December 23, 2021 by Kristina Panos 30 Comments

Well, this is a pleasant surprise: it seems that industrial designer [Eric Strebel] recently got a hold of an industrial sewing machine to tackle the softer side of prototyping. What doesn’t surprise us is that he did some upgrades to make it more user-friendly. Check them out in the video embedded below.

So, what’s the difference between a machine like this and what you might have around the house? Domestic sewing machines have a motor about the size of your fist, and it’s inside the machine’s body. Modern domestics can do light-duty work, but they can’t handle making bags and upholstery or sewing a bunch of layers of any material together. Industrial machines have either clutch or servo motors that are easily five times the size of a domestic’s motor, and are built into the table along with the machine.

[Eric] found this Pfaff 463 on Craigslist. It was built somewhere around 1950, and it only does one thing — a single-needle, straight stitch, forward or reverse — but it will do it through damn near anything you want (unlike those computerized hunks of plastic made for home use nowadays). Again, these machines are always built into a table, and they come with a lamp. While the machine itself may be a workhorse, the light is wimpy, so [Eric] replaced it with a goose-neck LED light that has a magnet for sticking it anywhere light is required around the machine.

No matter the size, electric sewing machines are driven with a foot pedal. On a domestic, the pedal is loose and you just put it on the floor wherever you want, but industrial foot pedals are built into the table frame. [Eric] drilled a bunch of new holes in the side of the pedal so he can move the connecting rod closer to the pivot point. This gives him better control with less footwork.

The biggest, baddest upgrade [Eric] did was to the motor. Although there was nothing wrong with the original clutch motor, it makes the machine go very fast so that garment workers can fulfill their quotas. Because of this, it’s difficult to control. He upgraded to a brushless DC servo motor for greater precision and easier prototyping. He got really lucky, too, because it mounted directly into the old holes.

We agree wholeheartedly with [Eric]’s sentiment about old sewing machines, or any old machine for that matter. They tend to be overbuilt because planned obsolescence wasn’t a thing yet. If you can’t afford or find an industrial, an old Singer or something similar will likely serve your purpose, as long as you use the right needle.

If you already have an old domestic machine sitting around, you might be able to breathe new life into it with a 3D printer.

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Stencil Vacuum-Assist Helps Avoid The Heartbreak Of Smeared Solder Paste

December 22, 2021 by Dan Maloney 9 Comments

While using a stencil should make solder paste application onto PCBs a simple affair, there are a number of “gotchas” that make it more art than science. Luckily, there are tools you can build, like this 3D-printed vacuum-assist stencil jig, that take a little of the finesse out of the process.

For those who haven’t had the pleasure, solder paste stencils are often used to make the job of applying just the right amount of solder paste onto the pads of a PCB, and only on the pads. The problem is that once the solder paste has been squeegeed through the holes in the stencil, it’s not easy to remove the stencil without smearing. [Marius Heier]’s stencil box is essentially a chamber that attaches to a shop vac, along with a two-piece perforated work surface. The center part of the top platform is fixed, while the outer section moves up and down on 3D-printed springs.

In use, the PCB is placed on the center fixed platform, while the stencil sits atop it. Suction pulls the stencil firmly down onto the PCB and holds it there while the solder paste is applied. Releasing the suction causes the outer section of the platform to spring up vertically, resulting in nice, neat solder-covered pads. [Marius] demonstrates the box in the video below, and shows a number of adapters that would make it work with different sized PCBs.

If you think you’ve seen a manual vacuum stencil box around here recently, you’re right — we featured one by [UnexpectedMaker] not too long ago.

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Make Your Own Chain Link Fencing

December 21, 2021 by Lewin Day 22 Comments

If you find yourself in need of chain link fencing, you’d probably just head down to the hardware store. However, [The Q] has shown us that you can make your own at home with a simple machine.

The build starts with a length of pipe, into which spiral slots are cut with an angle grinder. This pipe is the forming tool which shapes the wire into the familiar chain-link design. The pipe is then welded onto a backing plate, and fitted with a removable handcrank that turns a flat bar. Feed wire into the spiral groove, turn the crank, and out comes wire in the shape required.

From there, formed lengths of wire can be linked up into a fence of any desired size. Of course, fastening each end of the fence is left as an exercise for the reader, and the ends are sharp and unfinished. However, if you don’t like the chain link fencing on sale at your local hardware store, or you want to weave your own in some fancy type of wire, this machine could be just the thing you need.

We’ve seen similar designs before too, but on more of a doll-house scale. Video after the break.

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Your Next Oscilloscope Might Be Optical

December 19, 2021 by Al Williams 12 Comments

What’s better than a 100MHz scope? How about an optical one? Researchers at the University of Central Florida think that’s just the ticket, and they’ve built an oscilloscope that can measure the electric field of light. You can find the full paper online.

Reading the electrical field of light is difficult with traditional tools because of the very high frequency involved. According to [Michael Chini], who worked on the new instrument, the oscilloscope can be as much as 10,000 times faster as a conventional one.

The measurement of a few cycles of light requires some special techniques as you might expect. According to the paper:

[A]n intense fundamental pulse with a central wavelength of 3.4 µm creates charge packets in the pixels of a silicon-based image sensor via multiphoton excitation, leading to detectable photocurrents. The probability of excitation is perturbed by the field of a weak perturbation pulse, leading to a modulation in the excitation probability and therefore in the magnitude of the detected photocurrent. We have previously shown that, for collinear fundamental and perturbation pulses, the dependence of the modulation in the excitation probability on the time delay between the two pulses encodes the time-varying electric-field waveform of the laser pulse. Here, by using a crossed-beam geometry with cylindrical focusing, we map the time delay onto a transverse spatial coordinate of the image sensor chip to achieve single-shot detection.

Did you get that? In other words, instead of measuring the light pulse directly, they measure the change it makes on another known signal. We think…

Unless you’re moving high-speed data across fiber optic, we aren’t sure you really need this. However, the concept is intriguing and not previously unheard of. For example, we’ve seen capacitance meters that measure the change in frequency caused by adding an unknown capacitor into an existing oscillator.

If you want something more conventional, maybe look at some popular scopemeters. Of course, something this high speed might be able to apply time-domain reflectometry to fiber optics. Maybe.

3D Printing A Cyclonic Dust Separator

December 17, 2021 by Lewin Day 20 Comments

[rctestflight] recently purchased a big CNC router, and that meant it was time to arrange for some dust extraction in the workshop. Naturally, he set about building this himself!

Using a shop vac is fine at smaller scales, but they can quickly be filled up on bigger jobs. To stop it getting filled up as quickly and wasting vacuum bags, [rctestflight] wanted to build a 3D-printed cyclonic separator to catch and dump the heavier-than-air particles from the routing process into an attached bucket.

[rctestflight] trialed a variety of designs, from a quad cyclone, to a large single cyclone and even a triple-series design. A diffuser design was also built, that aims to slow the air flow to the point where particles drop out of the air stream. At the end of the day, the large mono-cyclone design proved to be the most effective at removing particles from the airstream.

Fundamentally, if you’re making lots of dust, a cyclonic separator is a great way to go about dealing with the problem. We’ve seen similar builds scaled up to deal with the needs of a whole workshop, too. Video after the break.

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