Volume Controller Rejects Skeumorphism, Embraces The Physical

July 9, 2025 by Tyler August 33 Comments

The volume slider on our virtual desktops is a skeuomorphic callback to the volume sliders on professional audio equipment on actual, physical desktops. [Maker Vibe] decided that this skeuomorphism was so last century, and made himself a physical audio control box for his PC.

Since he has three audio outputs he needs to consider, the peripheral he creates could conceivably be called a fader. It certainly has that look, anyway: each output is controlled by a volume slider — connected to a linear potentiometer — and a mute button. Seeing a linear potentiometer used for volume control threw us for a second, until we remembered this was for the computer’s volume control, not an actual volume control circuit. The computer’s volume slider already does the logarithmic conversion. A Seeed Studio Xiao ESP32S3 lives at the heart of this thing, emulating a Bluetooth gamepad using a library by LemmingDev. A trio of LEDs round out the electronics to provide an indicator for which audio channels are muted or active.

Those Bluetooth signals are interpreted by a Python script feeding a software called Voicmeeter Banana, because [Maker Vibe] uses Windows, and Redmond’s finest operating system doesn’t expose audio controls in an easily-accessible way. Voicmeeter Banana (and its attendant Python script) takes care of telling Windows what to do.

The whole setup lives on [Maker Vibe]’s desk in a handsome 3D printed box. He used a Circuit vinyl cutter to cut out masks so he could airbrush different colours onto the print after sanding down the layer lines. That’s another one for the archive of how to make front panels.

If volume sliders aren’t doing it for you, perhaps you’d prefer to control your audio with a conductor’s baton.

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Fastener Fusion: Automating The Art Of Counting

July 6, 2025 by Matt Varian 7 Comments

Counting objects is an ideal task for automation, and when focusing on a single type of object, there are many effective solutions. But what if you need to count hundreds of different objects? That’s the challenge [Christopher] tackled with his latest addition to his impressive automation projects. (Video, embedded below.)

[Christopher] has released a series of videos showcasing a containerized counting system for various fasteners, available on his YouTube channel. Previously, he built remarkable devices to count and sort fastener hardware for automated packaging, but those systems were designed for a single fastener type. He effectively highlights the vast complexity of the fastener ecosystem, where each diameter has dozens of lengths, multiple finishes, various head shapes, and more.

To address this, he developed a machine that accepts standardized containers of fastener hardware. These uniform boxes can hold anything from a small M2 countersunk screw to a large M8 cap head bolt and everything in between. To identify the loaded box and determine the appropriate operations, the machine features an RFID reader that scans each box’s unique tag.

Once a box is loaded, the machine tilts it to begin counting fasteners using a clever combination of moving platforms, an optical sensor, and gravity. A shelf first pushes a random number of fasteners onto an adjustable ledge. A second moving platform then sweeps excess fasteners off, leaving only those properly aligned. It’s no surprise this system has nine degrees of freedom. The ledge then moves into view of a sensor from a flatbed scanner, which detects object locations with an impressive 0.04 mm resolution across its length—remarkable for such an affordable sensor. At this point, the system knows how many fasteners are on the ledge. If the count exceeds the desired number, a sloped opening allows the ledge to lift just high enough to release the correct amount, ensuring precision.

The ingenuity continues after the initial count. A secondary counting method uses weight, with a load cell connected to the bin where fasteners drop. A clever over-center mechanism decouples the tilting system from the load cell to ensure accurate readings. We love automation projects, and this one incorporates so many ingenious design elements that it’s sure to inspire others for their future endeavors.

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Turbine Blower 3D Prints Every Part, Including Triple Planetary Gears

June 29, 2025 by Donald Papp 18 Comments

There was a time when print-in-place moving parts were a curiosity, but [Tomek] shows that things are now at a point where a hand-cranked turbine blower with integrated planetary gears can be entirely 3D printed. Some assembly is needed, but there is no added hardware beyond the printed parts. The blower is capable of decent airflow and can probably be optimized even further. Have a look at it work in the video below.

Every piece being 3D printed brings a few advantages. Prefer the hand crank on the other side? Simply mirror everything. Want a bigger version? Just scale everything up. Because all of the fasteners are printed as well as the parts, there’s no worry about external hardware no longer fitting oversized holes after scaling things up (scaling down might run into issues with tolerances, but if you manage an extra-small version, we’d love to hear about it).

There are a few good tips that are worth keeping in mind when it comes to print-in-place assemblies with moving parts. First, changing the seam location for each layer to ‘Random’ helps make moving parts smoother. This helps prevent the formation of a seam line, which can act as a little speed bump that gets in the way of smooth movement.

The other thing that helps is lubrication. A plastic-safe lubricant like PTFE-based Super Lube is a handy thing to have around the workshop and does wonders for smoothing out the action of 3D-printed moving parts. And we can attest that rubbing candle wax on mating surfaces works pretty well in a pinch.

One downside is that the blower is noisy in operation. 3D printed gears (and even printed bearings) can be effective, but do contribute to a distinct lack of silence compared to their purpose-built versions.

Still, a device like this is a sign of how far 3D printing has come, and how it enables projects that would otherwise remain an idea in a notebook. We do love 3D-printed gears.

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Building A 3D-Printed RC Dump Truck

June 27, 2025 by Lewin Day 1 Comment

Whatever your day job, many of us would love to jump behind the controls of a dump truck for a lark. In the real world, that takes training and expertise and the opportunity is denied to many of us. However, you can live out those dreams on your desk with this 3D-printed build from [ProfessorBoots.]

The build exists as two separate parts—the tractor, and the trailer. The tractor is effectively a fairly straightforward custom RC build, albeit with a few additional features to make it fit for purpose. It’s got six wheels as befitting a proper semi, and it has a nifty retractable magnetic hitch mechanism. This lets it hook up to various trailers and unhitch from them as desired, all from a press on the remote. The hitch also has provision for power and control lines that control whatever trailer happens to be attached.

As for the trailer, it’s a side-dumper that can drop its load to the left or right as desired. The dumping is controlled via a linear actuator using a small DC motor and a threaded rod. A servo controls a sliding locking mechanism which determines whether the truck dumps to the left or right as the linear actuator rises up.

The design video covers the 3D printed design as well as some great action shots of the dump truck doing its thing. We’ve featured some builds from [ProfessorBoots] before, too, like this neat 3D-printed forklift . Video after the break.

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Spiral Connector Makes Fastener-Free Assemblies

June 20, 2025 by Donald Papp 11 Comments

[Anton Gaia]’s SPIRAL sculpture resembles an organizer or modern shelving unit, but what’s really interesting is how it goes together. It’s made entirely from assembling copies of a single component (two, if you count the short ‘end pieces’ as separate) without a fastener in sight. [Anton] made the 3D model available, so check it out for yourself!

The self-similar design of the joint, based on the golden spiral, makes a self-supporting joint that requires neither glue nor fasteners.

The ends of each part form a tight, spiral-shaped joint when assembled with its neighbors. Parts connect solely to themselves without any need of fasteners or adhesives.

The end result is secure, scalable, and with a harmonious structure that is very pleasing to look at. Small wonder [Anton] used it as the basis for artistic work. You can see more pictures here.

The design of the joint is based on the golden spiral (which it turns out is also a pretty useful chicken coop architecture.)

The parts lend themselves quite well to 3D printing, and we’d like to take a moment to appreciate that [Anton] shared the .step file instead of just an STL. STEP (or STP) files can be imported meaningfully into CAD programs, making it much easier to incorporate the design into one’s own work. STEP is also supported natively in many 3D printer slicers, so there’s no need to convert formats just to print them.

A brief video describing SPIRAL is embedded just below, with a closer look at how the pieces fit together.

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Tune In To “Higher Lower”, The Minimal Handheld Electronic Game

June 4, 2025 by Donald Papp 8 Comments

[Tommy] has a great write-up about designing and building a minimalistic handheld electronic game called “Higher Lower”. It’s an audio-driven game in which the unit plays two tones and asks the player to choose whether the second tone was higher in pitch, or lower. The game relies on 3D printed components and minimal electronics, limiting player input to two buttons and output to whatever a speaker stuck to an output pin from an ATtiny85 can generate.

Fastener-free enclosure means fewer parts, and on the inside are pots for volume and difficulty. We love the thoughtful little tabs that hold the rocker switch in place during assembly.

Gameplay may be straightforward, but working with so little raises a number of design challenges. How does one best communicate game state (and things like scoring) with audio tones only? What’s the optimal way to generate a random seed when the best source of meaningful, zero-extra-components entropy (timing of player input) happens after the game has already started? What’s the most efficient way to turn a clear glue stick into a bunch of identical little light pipes? [Tommy] goes into great detail for each of these, and more.

In addition to the hardware and enclosure design, [Tommy] has tried new things on the software end of things. He found that using tools intended to develop for the Arduboy DIY handheld console along with a hardware emulator made for a very tight feedback loop during development. Being able to work on the software side without actually needing the hardware and chip programmer at hand was also flexible and convenient.

We’ve seen [Tommy]’s work before about his synth kits, and as usual his observations and shared insights about bringing an idea from concept to kit-worthy product are absolutely worth a read.

You can find all the design files on the GitHub repository, but Higher Lower is also available as a reasonably-priced kit with great documentation suitable for anyone with an interest. Watch it in action in the video below.

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Add Wood Grain Texture To 3D Prints – With A Model Of A Log

June 3, 2025 by Donald Papp 34 Comments

Adding textures is a great way to experiment with giving 3D prints a different look, and [PandaN] shows off a method of adding a wood grain effect in a way that’s easy to play around with. It involves using a 3D model of a log (complete with concentric tree rings) as a print modifier. The good news is that [PandaN] has already done the work of creating one, as well as showing how to use it.

The model of the stump — complete with concentric tree rings — acts as a modifier for the much-smaller printed object (in this case, a small plate).

In the slicer software one simply uses the log as a modifier for an object to be printed. When a 3D model is used as a modifier in this way, it means different print settings get applied everywhere the object to be printed and the modifier intersect one another.

In the case of this project, the modifier shifts the angle of the fill pattern wherever the models intersect. A fuzzy skin modifier is used as well, and the result is enough to give a wood grain appearance to the printed object. When printed with a wood filament (which is PLA mixed with wood particles), the result looks especially good.

We’ve seen a few different ways to add textures to 3D prints, including using Blender to modify model surfaces. Textures can enhance the look of a model, and are also a good way to hide layer lines.

In addition to the 3D models, [PandaN] provides a ready-to-go project for Bambu slicer with all the necessary settings already configured, so experimenting can be as simple as swapping the object to be printed with a new 3D model. Want to see that in action? Here’s a separate video demonstrating exactly that step-by-step, embedded below.

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