3D printed enclosure

98 Articles

ZSWatch: This OSHW Smart Watch Is As DIY As It Gets

January 16, 2023 by 17 Comments

We say it often, but it’s worth repeating: this is the Golden Age of making and hacking. Between powerful free and open source software, low-cost PCB production, and high resolution 3D printers that can fit on your desk, a dedicated individual has everything they need to make their dream gadget a reality. If you ever needed a reminder of this fact, just take a look at the ZSWatch.

When creator [Jakob Krantz] says he built this MIT-licensed smart watch from scratch, he means it. He designed the 4-layer main board, measuring just 36 mm across, entirely in KiCad. He wrote every line of the firmware, and even designed the 3D printable case himself. This isn’t some wearable development kit he got off of AliExpress and modified — it’s all built from the ground up, and all made available to anyone who might want to spin up their own version.

The star of the show is the nRF52833 SoC, which is paired with a circular 1.28″ 240×240 IPS TFT display. The screen doesn’t support touch, so there’s three physical buttons on the watch for navigation. Onboard sensors include a LIS2DS12 MEMS accelerometer and a MAX30101EFD capable of measuring heartrate and blood oxygen levels, and there’s even a tiny vibration motor for haptic feedback. Everything’s powered by a 220 mAh Li-Po battery that [Jakob] says is good for about two days — afterwards you can drop the watch into its matching docking station to get charged back up.

As for the software side of things, the watch tethers to a Android application over Bluetooth for Internet access and provides the expected functions such as displaying the weather, showing notifications, and controlling music playback. Oh, and it can tell the time as well. The firmware was made with extensibility in mind, and [Jakob] has provided both a sample application and some basic documentation for would-be ZSWatch developers.

While an unquestionably impressive accomplishment in its current form, [Jakob] says he’s already started work on a second version of the watch. The new V2 hardware will implement an updated SoC, touch screen, and an improved charging/programming connector. He’s also looking to replace the 3D printed case for something CNC milled for a more professional look.

The ZSWatch actually reminds us quite a bit of the Open-SmartWatch project we covered back in 2021, in that the final result looks so polished that the average person would never even take it for being DIY. We can’t say that about all the smartwatches we’ve seen over the years, but there’s no question that the state-of-the-art is moving forward for this kind of thing in the hobbyist space.

Audio Amp Puts VFDs To Work In An Unusual Way

December 8, 2022 by 14 Comments

It’s safe to say that most projects that feature a VFD emphasize the “D” aspect more than anything. Vacuum fluorescent displays are solid performers, after all, with their cool blue-green glow that’s just the right look for lots of retro and not-so-retro builds. But that doesn’t mean there aren’t applications that leverage the “V” aspect, such as this nifty audio preamp using VFDs as active components.

The inspiration behind [JGJMatt]’s build came from the Korg Nutube line of VFD-based low-voltage dual-triode vacuum tubes. Finding these particular components a little on the expensive side, [JGJMatt] turned to the old standby DM160 VFD indicator tube, which is basically just a triode, to see how it would fare as an amp. The circuit takes advantage of the low current and voltage requirements of the VFDs — the whole thing runs from a USB boost converter — by wedging them between a 2N3904 input stage and a 2N2007 MOSFET output. There’s a mix of SMD and through-hole components on the custom-etched PCB, with a separate riser card to show off the VFDs a little bit through the front panel of the 3D printed case.

All in all, we find this little amp pretty cool, and we love the way it puts a twist on the venerable VFD. We’ve seen similar VFD amps before, but this one’s fit and finish really pays off.

DIY Fume Extractor With ATtiny13 Speed Control

September 4, 2022 by 15 Comments

Let’s be honest, commercially-available soldering fume extractors are cheap enough that you probably don’t need to build one yourself. But it still makes for a good starter project, especially if you go out of your way to really flex your maker muscles like [Arnov Sharma] did with this tidy build.

All the hallmarks of modern hardware making are on display here — you’ve got the 3D printed enclosure, a motor salvaged from a cheap toy quadcopter, and a custom PCB which uses the ATtiny13 and an AO4406 MOSFET to implement a PWM speed control.

The first press of the button starts the motor off at max speed, but keep pushing it, and the motor’s speed will ramp down until it turns off entirely. There’s even a TP4056 charge controller to top off the internal 18650 cell when the fume extractor is connected to a USB power source.

Is it over-engineered? Perhaps. But projects like these are a great opportunity to practice your skills, whether it’s PCB design or creating bespoke 3D printed enclosures. In the era of cheap 32-bit microcontrollers, it’s also refreshing to see hackers still dragging the ATtiny from time to time.

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A disassembled Game Boy-shaped Hackintosh

This Big 3D-Printed Game Boy Actually Runs MacOS

April 3, 2022 by 3 Comments

While mobile gaming has largely moved to smartphones these days, the classic Game Boy remains a hugely popular platform for retro enthusiasts, owing in no small part to its enormous library of quality games. The original Game Boy hardware is pretty much bulletproof, but feels a bit outdated today because it lacks modern conveniences like a large, backlit display or a rechargeable battery.

[iketsj] wanted to build a modern take on the Game Boy design and designed what’s in effect a 3D-printed, oversized copy of the classic handheld powered by a modern single-board computer. Most people would have gone for something obvious like a Raspberry Pi running Linux, but not [Ike]: he decided to go for a LattePanda Alpha board and run macOS Monterey on it. That makes this a Hackintosh, and probably one of the last ones as well since Apple is busy migrating all of its products onto its own proprietary CPUs.

The LattePanda also has an Arduino integrated on its board, which is used to read out the Game Boy’s buttons as well as the resistive touch screen. It communicates with the macOS system through a Python script that emulates mouse movements and keypresses. Sadly, the touch function is not working because [Ike] accidentally damaged the touch-sensitive system while trying to slim down the display module. Still, the seven pushbuttons are more than enough when running a Game Boy emulator, and there’s also a USB connector available to connect external peripherals like a keyboard, mouse or monitor.

We’ve seen several great Game Boy projects over the years: some made from brass, some very wide, and some that stuff modern computing platforms inside an original Game Boy case. Combining a Game Boy with a Hackintosh is definitely a new development, though it matches well with [Ike]’s history of unusual Hackintosh designs. Continue reading “This Big 3D-Printed Game Boy Actually Runs MacOS” →

World’s Worst I/O Dock Doesn’t Deserve Elegant Fix

March 19, 2022 by 63 Comments

Even spendy commercial products can end up being lemons. This is something [Mike Buss] is familiar with, as he had the misfortune of being stuck using what he declares is the world’s worst USB hub, and it’s not even a mystery discount device from overseas: it’s an HP Thunderbolt Dock G2. It is a sort of combination I/O dock and USB hub, and it caused him no end of frustration until he “fixed” it with a crude workaround.

The problems with [Mike]’s dock come down to two major issues. The first is that the USB-C connection will, if moved even the slightest amount, instantly trigger a disconnect from the host computer. Frankly, that sounds like a defect, but that’s not all. The other issue is that the whole top of the device is actually a giant, hyper-sensitive button. Even a stern gaze seems to be enough to cause it to activate. What does the button do? It puts the host computer to sleep; something that we all agree should suffer from as few false activations as possible.

We’ll spoil the surprise by revealing that the “fix” was nothing more than putting a 3D printed enclosure around the troublesome device, as shown in the image above. Keeping the dock covered and perfectly still at least prevents the two aforementioned issues, and that’s good enough for [Mike].

The curious part of all this is just how badly the device’s design affected normal use. We’d suspect a defect or malfunction, but a cursory search of reviews online suggests [Mike]’s experience isn’t unique. It’s certainly not the first poorly-designed product we’ve seen fixed by a new enclosure, but some problems just aren’t worth the effort of a more elegant solution.

This Parametric Project Box Generator Is Super Easy

January 31, 2022 by 8 Comments

When it comes to taking an idea from concept to prototype reality, depending on the type of project, there can be quite a few sub-tasks along the way. Take for example, your latest electronic widget design. You’ve finished the schematic, and the PCB layout is a work of art (if you do say so yourself) but having that kicking around on the desk unprotected with wires dangling is not the end game. Now you’ve got to make an enclosure of some kind, and I don’t know about you, but this is the bit where this scribe struggles a little to get something to fit nice. Even if you’ve got the latest 3D printer dialed in to within a gnat’s whisker of perfection, you’ve still got to come up with the design, and those dimensions need to be really accurate. So, for those of us who are great at the PCB, but suck at the enclosure, [Willem Aandewiel] has been busy making the tool just for you, with his PCB-orientated Yet Another Parametric Projectbox generator (YAPP.)

Defining the PCB mounting points w.r.t. the PCB outline

Without hesitation you can head over to the YAPP GitHub, grab that sweet OpenSCAD code, and get cracking with the demos. Provided for your convenience are a number of examples for enclosing some common items, such as Arduinos and ESP32 modules, so you can use those as a springboard to get your own code in place. YAPP works based off the PCB — by specifying programmatically since this is OpenSCAD — outer dimensions, mounting post locations first. Next you define openings in the six faces of the box, and the tool happily spits out a platter with the base and lid ready to drop into Cura (or your slicer of choice) What could be easier?

End face cutouts

And before you start on non-rectangular designs, this is a rectangular box generator for rectangular PCBs. That is all this is designed for, and as far as we can tell, it does that one job well.

Of course, this is by no means the first enclosure generator to grace these pages, far from it. Here’s one for starters. If you’re here for tips to help make better designs, check this out, and finally 3DHubs also has a nice guide for you. Happy printing!

Tiger Boy Advance Is A 90s Kid Dream Come True

January 7, 2022 by 6 Comments

From the release of the DMG-01 in 1989 until the final Micro variant hit store shelves in 2005, the Nintendo Game Boy line represented the epitome of handheld gaming for hundreds of millions of players. But that’s not to say there weren’t a wide array of other handheld systems that aimed to chip away at the Japanese gaming giant’s monopoly. SEGA and Sony released high-tech systems that brought impressive technical innovations, while Tiger Electronics famously took the opposite approach with ultra-cheap handhelds that leveraged simplistic games based on popular children’s franchises.

[Chris Downing] had to make do with these budget Tiger games as a child, and now as an adult, he’s determined to made things right with the Tiger Boy Advance. As the name implies, this retro hybrid combines the look and feel of a branded Tiger game with the power and software compatibility of a legitimate Nintendo Game Boy Advance (GBA) circa 2001. It even sprinkles in some modern niceties, like USB-C charging and a backlit display. While most of its charm is probably lost on anyone who didn’t grow up within a fairly narrow range of years, the video below seems to prove that even modern kids can appreciate this one-of-a-kind creation.

From an electronics standpoint, the system is essentially just a gutted GBA crammed into a 3D printed approximation of an old Tiger game from around the mid 1990s. But what makes this project special is the nostalgia-fueled attention to detail that [Chris] brings to the table.

Take for example the custom manufactured faceplate that combines artwork from some of the era’s best known games. Getting the image printed on the back of the CNC-cut piece of clear acrylic proved to be quite a challenge, but the final result looks incredibly professional. Instead of using the GBA’s stock buttons and directional pad, [Chris] decided to 3D print replacements that mimic the look of the original Tiger controls. It all culminates in a device that perfectly recreates the unique look of the original Tiger games.

Some will argue that he’d have done better to equip the system with a Raspberry Pi Zero 2 and the latest build of RetroPie, and frankly, it’s easy to see the appeal of going that route. But [Chris] didn’t make this for us, he built it to encapsulate a very specific time from his own childhood. We’re just glad that the technology now available to the individual maker allowed him to turn this particular dream into reality.

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