A Power Bank For Soldering On The Go

If you have a portable gadget, the chances are you’ve probably used power banks before. What few could have predicted when these portable battery packs first started cropping up is that they would one day be used to power soldering irons. Dissatisfied with the options currently available on the market, [Franci] writes in with his own power bank specifically designed for use with his TS80 portable soldering iron.

The electronics side of this build is simple and easy to replicate, with 4 18650 Li-ion cells standard to most high-capacity power banks and an off-the-shelf Fast Charge module serving as the brains of the operation. The beauty of this project however lies in the design of the actual case, completely custom-made from scratch to be 3d printed.

Unlike most power banks, where the outputs stick out to the side and leave the connectors prone to being bumped and damaged, [Franci] engineered his case so the ports are stacked on top and facing inwards. That way, USB plugs are contained within the footprint of the power bank’s body, and therefore protected from bending or snapping off in the socket. He also gracefully provides all instructions needed to make your own, including a wiring guide and a reminder about safety when dealing with battery packs.

If you’re unfamiliar with the TS80 soldering iron, we’ve featured the younger sibling of the TS100 in a previous post. And if you think this power bank is too simple for you, don’t worry, we’ve got you covered.

A Work Of Art That Also Receives AM And SSB

Over the winter, [Michael LeBlanc] thought a good way to spend his time during those long dark nights would be to scratch build his own direct conversion receiver. He was able to find plans for such a project easily enough online, but where’s the fun in following instructions? The final result incorporates what he found online with his own unique tweaks and artistic style.

[Michael] based his receiver on a modified approach to the DC40 created by [Ashhar Farhan], a name likely familiar to readers involved in amatuer radio. He further modified the design by swapping out the audio amplifier for a TDA2003A, and bolted on a digital tuner by way of an Arduino and a Si5351 clock generator. There’s a small OLED to show the current frequency, which is adjusted with a high-quality Bourns EM14 optical encoder so he can surf the airwaves in the comfort and style.

The digital tuner mated to the analog DC40 receiver gives the radio an interesting duality, which [Michael] really embraces with his enclosure design. From a practical standpoint he wanted to keep the two halves of the system in their own boxes to minimize any interference, but the 3D printed case exaggerates that practical consideration into a fascinating conversation piece.

The analog and digital compartments are askew, and their rotary controls are on opposite sides. The radio looks like it might topple over if it wasn’t for the fact that the whole thing is bolted together, complete with brass inserts for the printed parts. The integrated carry handle at the top somehow manages to make it look vintage and ultra-modern at the same time. Rarely do you see a printed enclosure that’s both meticulously designed inside and aesthetically pleasing externally. [Michael] earned his 3D Printing Merit Badge for sure with this one.

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Overengineering The Humble USB Power Bank

Back in the flip phone days, you could get through the whole weekend before you had to even think about plugging the thing in. But as the processing power of our mobile devices increased, so to did their energy consumption. Today you’re lucky if your phone doesn’t die before you make it home at the end of the day. To avoid the horrors of having to live without their mobile devices, many people have resorted to lugging around small “power banks” to keep their phones topped off.

That said, the “Ultimate 18650 Power Bank” created by [Kennedy Liu] is on a whole new level. Only true Road Warriors need apply for this particular piece of kit. Inside the 3D printed enclosure is…well, pretty much everything. It’s got an internal inverter to power your AC devices, a Qi wireless charging coil, an adjustable DC output, displays for all relevant voltages, and naturally plenty of USB ports to charge your gadgets. Oh, and some RGB LEDs tossed in for good measure.

[Kennedy] packed a lot of hardware into this relatively small package, and in the video after the break, shows off exactly how everything is arranged inside of this power bank. A big part of getting the whole thing together is the 3D printed frame, which includes carefully designed insets for all of the key components. So if you want to build your own version, you’ll need to get the exact same hardware he used to make sure the puzzle fits together. Luckily, he’s provided links for all the relevant components for exactly that purpose.

Now, you might be wondering about the wisdom of packing all this electronic gear into a thermoplastic enclosure. But [Kennedy] has thought about that; in addition to tacking a heatsink onto pretty much everything, he’s added fans for active cooling and a fairly robust thermal overload protection scheme. By mounting thermally controlled switches to the heatsinks of the high-output components, the system can cut power to anything getting too hot before it has a chance to melt the plastic (or worse).

Most of the DIY power banks we’ve seen in the past have been little more than a simple collection of 18650 cells, so it’s interesting to see one with so much additional functionality packed in. Admittedly some elements of the construction are, to quote the great Dave Jones, “a bit how ya doin.” But with some refinements we think it would be a very handy device to have in your arsenal.

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WOPR: Building Hardware Worth Sharing

It wouldn’t be much of a stretch to assume that anyone reading Hackaday regularly has at least progressed to the point where they can connect an LED to a microcontroller and get it to blink without setting anything on fire. We won’t even chastise you for not doing it with a 555 timer. It’s also not a stretch to say if you can successfully put together the “Hello World” of modern electronics on a breadboard, you’re well on the way to adding a few more LEDs, some sensors, and a couple buttons to that microcontroller and producing something that might come dangerously close to a useful gadget. Hardware hacking sneaks up on you like that.

Here’s where it gets tricky: how many of us are still stuck at that point? Don’t be shy, there’s no shame in it. A large chunk of the “completed” projects that grace these pages are still on breadboards, and if we had to pass on every project that still had a full-on development board like the Arduino or Wemos D1 at its heart…well, let’s just say it wouldn’t be pretty.

Of course, if you’re just building something as a personal project, there’s often little advantage to having a PCB spun up or building a custom enclosure. But what happens when you want to build more than one? If you’ve got an idea worth putting into production, you’ve got to approach the problem with a bit more finesse. Especially if you’re looking to turn a profit on the venture.

At the recent WOPR Summit in Atlantic City, there were a pair of presentations which dealt specifically with taking your hardware designs to the next level. Russell Handorf and Mike Kershaw hosted an epic four hour workshop called Strategies for your Projects: Concept to Prototype and El Kentaro gave a fascinating talk about his design process called Being Q: Designing Hacking Gadgets which together tackled both the practical and somewhat more philosophical aspects of building hardware for an audience larger than just yourself.

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The Only Cassette Player Worth Owning In 2019

Vinyl has the audiophiles to keep it relevant, and CDs still have the people who are scared of streaming music, but who mourns for the cassette tape? Yesterday we would have said nobody, but now that [Igor Afanasyev] has unleashed his latest creation onto an unsuspecting world, we aren’t so sure anymore. A portable tape player that started as a $5 find from the Goodwill is now an outrageously gorgeous piece of electronic art thanks to 3D printing and a liberal application of LEDs.

After freeing the tape mechanism from the original enclosure and extraneous electronics like the AM/FM tuner, [Igor] got to work designing a retro styled enclosure for the hardware which would show off the complex electromechanical bits which would traditionally be hidden. With the addition of a clever 3D printed holder, he was even able to add microswitches under the original player’s buttons so he could detect the player’s current state without having to modify the electronics. This lets the finished player change the color of the RGB LEDs based on what it’s currently doing.

[Igor] came up with a very clever way of integrating light-up icons into the case by placing bright LEDs behind specially crafted thin sections of the print. It looked awesome in his tests, but after the considerable sanding, priming, and painting it took to turn the 3D printed parts into a production-quality enclosure, the LEDs are no longer visible on the final product. Even though they didn’t work in this particular case, we think it’s a brilliant technique worthy of stealing further research.

The detail that [Igor] but into this build is phenomenal. Seeing all the individual components he had to design and print to make the final product come together is really nothing short of inspirational. Projects like these are where 3D printing really shines, as trying to replicate this build with traditional manufacturing techniques would be an absolute nightmare.

If you can’t quite shake the feeling that you’ve seen this name or attention to detail before, it’s for good reason. Last year we covered another build showing the knack [Igor] has for turning the ordinary into the extraordinary.

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RetroPie NES Clock Tells You When It’s Game Time

We’ve all seen the 3D printed replicas of classic game consoles which house a Raspberry Pi; in fact, there’s a pretty good chance some of the people reading this post have one of their own. They’re a great way to add some classic gaming emulation to your entertainment center, especially compared to the bare PCB chic of just having a Pi hanging off your TV’s HDMI port.

[Victor Heid] loved the look of these miniature consoles, but wanted to challenge himself to design something that was also multi-functional and unique. So he decided to create an NES-inspired case for the Raspberry Pi 3 A+ that doubles as a LED matrix clock with a decidedly retro feel. Frankly, even if it was just a clock we would have been impressed with the final product; but the fact that it’s also a fully functional RetroPie build really goes above and beyond.

It should be obvious just looking at the completed product that [Victor] put a lot of effort into sanding and finishing the 3D printed case. But we don’t have to imagine the process, since he was kind enough to thoroughly detail the steps and materials he used. As you might have guessed, the short version is a lot of filler and a lot of time; but it’s worth looking at the complete write-up if you’ve ever considered trying to make your own printed parts look less…printed. His method of applying the lettering on the front of case using a laser printer, some Mod Podge, and a healthy dose of patience is also something you might want to file away for a future project.

The electronics for this project are exceptionally simple, as [Victor] used the Pimoroni Scroll pHAT HD rather than trying to roll his own LED matrix in such a limited space. So it was just a matter of connecting up the wires to the Pi’s GPIO header and getting the various bits of software talking to each other, which he also details for anyone who might be interested.

It’s been a few months since the Raspberry Pi 3 A+ was unveiled, and we’re finally starting to see projects that make use of the new board’s reduced footprint. The ability of hardware like the A+, combined with the lackluster attempts by manufactures to produce official “mini” systems, seems to have set the stage for hackers to once again outshine commercial offerings. Not that we’re complaining, of course.

Rock Out To The Written Word With BookSound

With his latest project, [Roni Bandini] has simultaneously given the world a new type of audiobook and music. Traditional audiobooks are basically the adult equivalent of having somebody read you a bedtime story, but BookSound actually turns the written word into electronic music. You won’t be able to boast to your friends that as a matter of fact, you have read that popular new novel, but at least you might be able to dance to it.

[Roni] says he’s still working on perfecting the word to music mapping, so the results shown in the video after the break are still a bit rough. But even in these early stages there’s no denying this is an exceptionally unique project, and we’re excited to see where it goes from here.

Inside the classy looking 3D printed enclosure is a Raspberry Pi, an OLED display, and the button and switch which make up the extent of the device’s controls. At the end of the arm is a standard Raspberry Pi Camera module, which gives the BookSound a bird’s eye view of the book to be songified.

To turn your favorite book into electronic beats, simply open it up, put it under the gaze of BookSound, and press the button on the front. Because the Raspberry Pi isn’t exactly a powerhouse, it takes about two minutes for it to scan the page, perform optical character recognition (OCR), and compose the track before you start to hear anything.

If you’re wondering what the secret sauce is to turn words into music, [Roni] isn’t ready to share his source code just yet. But he was able to give us a few high-level explanations of what’s going on inside BookSound. For example, to generate the song’s BPM, the software will count how many words per paragraph are on the page: so a book with shorter paragraphs will consequently have a faster tempo to match the speed at which the author is moving through ideas. Similarly, drum kicks are generated based on the number of syllables in each paragraph. In the future, he’s looking at adding “lyrics” by running commonly used words on the page through a text to speech engine and inserting them into the beat.

We’ve seen practical applications of OCR on the Raspberry Pi in the past and even similar looking book scanning arrangements. But nothing quite like BookSound before, which at this point, is really saying something.

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