3D Printed ESP8266 TV Is A Blast From The Past

July 23, 2020 by Tom Nardi 16 Comments

We’ve often said that one of the best applications for desktop 3D printing is the production of custom enclosures, but you certainly aren’t limited to an extruded version of the classic Radio Shack project box. As [Marcello Milone] shows with this very clever retro TV enclosure for the Wemos D1 Mini, 3D printing means your imagination is the only limit when it comes to how you want to package up your latest creation.

As nice as the printed parts are, it’s the little details that really sell the look. [Marcello] has bent a piece of copper wire into a circle to make a faux antenna with vintage flair, and while the ESP is connecting to the WiFi network, it even shows an old school TV test pattern on its 1.8″ TFT display.

In the video after the break you can see the device go through its startup routine, and while displaying the Hackaday Wrencher at boot might not be strictly on theme…we’ll allow it.

While you could certainly use this little enclosure for whatever ESP project you had in mind, [Marcello] says he’s building a distributed environmental monitoring network using HTU21D temperature and humidity sensors. It sounds like he’s still working on the software side of things though, so hopefully he posts an update when the functionality is fully realized.

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Designing 3D Printed Enclosures For KiCad PCBs

July 7, 2020 by Tom Nardi 16 Comments

If you’ve used KiCad before, you’re certainly familiar with the handy 3D view that shows you a rendered view of what your assembled board would look like. But as [Vadim Panov] explains, you can take this capability a step further. With a few extra tools and a little bit of know-how, you can leverage KiCad’s PCB renderings to make custom 3D printable enclosures.

The first step is to design the PCB as you normally would in KiCad. This could be an original PCB of your own invention, or a digital representation of an off-the-shelf model you want to build an enclosure for. If the latter, then the PCB doesn’t need to be 100% accurate; the goal is really just to get the big components into roughly the right areas so you can get the clearances right. Though obviously you’ll want to make sure the board’s outer dimensions and mounting hole locations are recreated as accurately as possible.

From there, [Vadim] recommends a tool called StepUp. This will take your PCB KiCad PCB files and create either a STEP or STL file of the assembled board which can be imported into your CAD package of choice. For the purposes of this demonstration he’s sticking with FreeCAD, as he likes the idea of it being a completely FOSS toolchain from start to finish.

Now that you have a model of the PCB in your CAD software, the rest is up to you. Naturally, there are existing enclosure models you can use such as the ones produced by the “Ultimate Box Maker” that we covered previously, but you could just as easily start building a new enclosure around the digital PCB.

Looking for a bit more guidance? As it so happens, our very own [Anool Mahidharia] will be presenting a class on how you can develop a KiCad + FreeCAD workflow as part of our recently launched HackadayU initiative.

Building An ESP32 Smart Power Strip From Scratch

June 10, 2020 by Tom Nardi 33 Comments

Surely the most straightforward way of creating a smart power strip would be to take an existing model and hack in some relays that you could fire with a WiFi-enabled microcontroller. But where’s the fun in that? Instead of repurposing a commercial power strip for his recent project, [Md Raz] decided to just build the whole thing himself.

The project started with a 3D printed enclosure that could hold the electronics and three panel mount sockets. The use of heat-set inserts makes it a bit more robust for future upgrade work, but otherwise it’s a fairly simple rectangular design. Nobody ever said a power strip had to be pretty, right? In addition to the panel mount sockets, there’s also a AC-DC converter to step mains voltage down to 5 VDC for the ESP32.

In addition to the microcontroller, the custom PCB in the power strip holds a trio of MOSFETs connected to AQH2223 solid state relay (SSR) chips. Once the ESP32 toggles the line attached to each MOSFET, the indicator LED above the outlet goes on and the appropriate SSR is thrown to turn on the power. With a simple web interface running on the microcontroller, all three outlets can be independently controlled from any device with a web browser.

If you’d like to limit your interaction with mains voltages, then we’ve seen some projects that commandeer the low-voltage side of a commercial smart power strip. But remember, putting a Raspberry Pi inside of a power strip might seem suspicious to some folks.

UV Phone Sanitizer Shows The Power Of Modern DIY

June 8, 2020 by Tom Nardi 94 Comments

Editor’s Update: According to the schematic for this project, SST-10-UV-A130-F405-00 (PDF) LEDs are used which produce 405nm UV-A light. The manufacturer, Luminus, does not recommend that part for disinfection or sterilization. Luminus sells UV-C LEDs for that purpose, generating 275-285nm. After publication the part number used was changed to and American Opto L933-UV265-2-20 which is a UV-C LED producing 265-278nm.

The global COVID-19 pandemic has had a serious impact on the hacking and making scene, though it hasn’t been all bad. Sure, shipping on average is taking a lot longer than we’d like when ordering parts, but otherwise being stuck at home has given many people far more time to work on their projects than they would have had otherwise. In some cases, it’s also been a reminder of just how far we’ve come in terms of what the dedicated individual is capable of producing within the confines of their own home.

As a perfect example, take a look at this UV sanitizer box built by [Md Raz]. Looking for a way to quickly and easily kill germs on smartphones and other small devices, he used the considerable capabilities afforded to the modern hacker to produce a professional-looking device in far less time than it would have if he had to outsource things like PCB manufacturing or injection molding.

Inside the 3D printed enclosure is an array of SMD UV-C LEDs that, according to the manufacturer’s specs, will destroy viruses and bacteria in 5 minutes. To make sure the LEDs are given enough time to do their job, [Md] is using an ATtiny85 to control the countdown and a seven segment display to let the user know how much longer they have to wait. All the electronics are held on PCBs produced with a BotFactory SV2 desktop PCB printer, but for those of us with somewhat more limited budgets, a mill or even a modified laser engraver could be used to produce similar boards.

With everything going on, there’s understandably been increased demand for germicidal lights. But unfortunately, some unscrupulous manufacturers are trying to take advantage of the situation. Being able to select the LEDs for this device based on their specifications is arguably just as important as how quickly it was produced. Though we’d still advise a position of “trust, but verify” when it comes to UV-C.

Join The Movement With This Mini Cyberdeck

June 5, 2020 by Tom Nardi 5 Comments

The global pandemic has given many people a lot more time at home, which has undoubtedly pushed an untold number of projects over the finish line. Unfortunately, it’s also disrupted global commerce and shipping to the point that getting parts can be a lot harder than we’d like. Which is why [facelesstech] decided to put together this exceptionally mobile cyberdeck out of things he already had laying around.

Now to be fair, his parts bin is perhaps a bit better stocked for this kind of thing than most. He’s built a couple of Raspberry Pi portables already, so the Pi Zero W, display, and battery management board were already kicking around. He just had to come up with a new 3D printed enclosure that holds it all together with a little bit of cyberpunk flair.

To that end, he’s done an excellent job of documenting the build and has released the STL files for the 3D printed components. All things considered, we’d say this is probably the most approachable cyberdeck design currently available; if you’ve been wondering what all the fuss is about with these bespoke little computers, this is an ideal project to get started with.

Keep in mind that the idea of a cyberdeck is to build something custom for yourself, so there’s no need to copy this build exactly. If you’re short on parts, you could forgo the battery powered aspect and just keep it tethered. The superfluous (but very cool) GX12 connectors could certainly be deleted as well, although at serious stylistic cost. You’ll probably need to order the specific keyboard that [facelesstech] designed the lower half of the device around, but it’s common enough that it shouldn’t be hard to track down. No matter which way you take it, this design is a great base to start from.

If you’re looking for something a bit more substantial and have the filament to burn, you might take a look at the VirtuScope to fulfill your offset screen needs.

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Queue Up Your Tracks With A Well Placed Hexagon

April 24, 2020 by Tom Nardi 11 Comments

Besides a few stalwart holdouts, most of us have have switched over listening to music in digital form, often via an online stream. As long as no data caps stand in your way, it’s a quick and easy way to listen to your favorite artists or discover new ones. But there’s something visceral about act of loading a piece of physical media into a player that can’t be replicated by just clicking or tapping on a screen.

Which is why [InfiniteVideo] put together this RFID playlist launcher peripheral. There’s an important distinction to be made here, as this device isn’t actually playing or even storing audio. A nearby Raspberry running Volumio handles the actual playback. This device is just an RFID reader with some clever tokens that the listener can use to select their favorite artists and albums with physical tokens. It’s certainly not a new concept, but we think the nuances of this particular build warrant a closer look.

The “player” consists of a ESP8266 with a MFRC522 RFID reader wired directly to the GPIO pins. The pair are housed in a rather large 3D printed enclosure, which at first might seem a bit excessive. But it turns out that [InfiniteVideo] is actually trying to replicate a crowd sourced project called Qleek which is based around a similarly chunky reader.

Likewise, the hexagon tiles are also lifted from the Qleek concept. But rather than being made out of wood as in the original, [InfiniteVideo] is printing those as well. Halfway during the process, the print is paused and an RFID sticker is placed in the middle of the hexagon. Once resumed, the RFID tag becomes permanently embedded in the tile with no visible seams to reveal how the trick was pulled off. With the addition of a suitable label, each printed hexagon gets associated with the desired album or artist in software.

This project is notable for its convenience and visual flair, but using RFID tags for media identification can also be a practical choice. It can be used as an assistive technology, or as a way for young children to easily interact with devices.

3D Print Your Way To A Bartop Arcade Cabinet

April 22, 2020 by Tom Nardi 3 Comments

Custom arcade machines have always been a fairly common project in the hacker and maker circles, but they’ve really taken off with the advent of the Raspberry Pi and turn-key controller kits. With all the internals neatly sorted, the only thing you need to figure out is the cabinet itself. Unfortunately, that’s often the trickiest part. Without proper woodworking tools, or ideally a CNC router, it can be tough going to build a decent looking cabinet out of the traditional MDF panels.

But if you’re willing to leave wood behind, [Gerrit Gazic] might have a solution for you. This bartop arcade, which he calls the simplyRetro D8, uses a fully 3D printed cabinet. He’s gone through the trouble of designing it so there are no visible screw holes, so it looks like the whole thing was hewn from a chunk of pure synthwave ore. He notes that this can make the assembly somewhat tricky in a few spots, but we think it’s a worthy compromise.

Given the squat profile of the simplyRetro, the internals are packed in a bit tighter than we’re accustomed to seeing in a arcade build. But there’s still more than enough room for the Raspberry Pi, eight inch touch screen HDMI panel, and all the controls. To keep things as neat as possible, [Gerrit] even added integrated zip tie mount points; a worthwhile CAD tip that’s certainly not limited to arcade cabinets.

[Gerrit] has included not only the STL files for this design, but also the Fusion 360 Archive should you want to make any modifications. There’s also a complete Bill of Materials, as well as detailed instructions on how to pull it all together. If you’ve ever wanted your own arcade machine but felt a bit overwhelmed about figuring out all the nuances on your own, the simplyRetro could be the project you’ve been waiting for.

Of course if you do have access to a CNC or laser cutter, then there are some designs you could produce quite a bit faster.