Alternate Threaded Inserts For 3D Prints

April 15, 2024 by Donald Papp 21 Comments

The usual way to put a durable threaded interface into a 3D print is to use a heat-set insert, but what about other options? [Thomas Sanladerer] evaluates a variety of different threaded inserts, none of which are actually made with 3D printing in mind but are useful nevertheless.

There are a number of other easily-available threaded inserts, including the rivnut (or rivet nut), chunky hex socket threaded inserts intended for wood and furniture, heli-coils or helical inserts (which resemble springs), self-tapping threaded inserts (also sold as thread adapters), and T-nuts or prong nuts. They all are a bit different, but he measures each one and gives a thorough rundown on how they perform, as well as offering his thoughts on what works best.

[Thomas] only tests M5 fasteners in this video, so keep that in mind if you get ideas and go shopping for new hardware. Some of the tested inserts aren’t commonly available in smaller sizes. Self-tapping threaded inserts, for example, are available all the way down to M2, but the hex socket threaded inserts don’t seem to come any smaller than M4.

These threaded inserts might be just what your next project calls for, so keep them in mind. Heat-set inserts are of course still a great option, and our own Sonya Vasquez can tell you everything you need to know about installing heat-set inserts into 3D printed parts in a way that leaves them looking super professional.

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2024 Home Sweet Home Automation: [HEX]POD – Climate Tracker And Digital Nose

March 27, 2024 by Dave Rowntree 9 Comments

[eBender] was travelling India with friends, when one got sick. Unable to find a thermometer anywhere during COVID, they finally ended up in a hospital. After being evacuated back home, [eBender] hatched an idea to create a portable gadget featuring a few travel essentials: the ability to measure body temperature and heart rate, a power bank and an illumination source. The scope evolved quite a lot, with the concept being to create a learning platform for environmental multi-sensor fusion. The current cut-down development kit hosts just the air quality measurement components, but expansion from this base shouldn’t be too hard.

ML for Hackers: Fiddle with that Tensor Flow

This project’s execution is excellent, with a hexagon-shaped enclosure and PCBs stacked within. As everyone knows, hexagons are the bestagons. The platform currently hosts SCD41 and SGP41 sensors for air quality, a BME688 for gas detection, LTR-308 for ambient light and motion, and many temperature sensors.

On top sits a 1.69-inch IPS LCD, with an OLED display on the side for always-on visualization. The user interface is completed with a joystick and a couple of buttons. An internal blower fan is ducted around the sensor array to pull not-so-fresh air from outside for evaluation. Control is courtesy of an ESP32 module, with the gory details buried deep in the extensive project logs, which show sensors and other parts being swapped in and out.

On the software side, some preliminary work is being done on training TensorFlow to learn the sensor fusion inputs. This is no simple task. Finally, we would have a complete package if [eBender] could source a hexagonal LCD to showcase that hexagon-orientated GUI. However, we doubt such a thing exists, which is a shame.

There are many air quality sensors on the market now, so we see a few hacks based on them, like this simple AQ sensor hub. Let’s not forget the importance of environmental CO2 detection; here’s something to get you started.

Retro Hackintosh Made From Retro Parts

March 25, 2024 by Bryan Cockfield 20 Comments

Apple as a company, has staked most of its future around being a “walled garden” where it controls everything from the hardware up through the user experience. In some ways this is good for users; the hardware is generally high quality and vetted by the company creating the software, making for a very uniform experience. This won’t stop some people from trying to get Apple’s operating systems and other software running on unapproved hardware though. These “Hackintosh” computers were much more common in the Intel era but this replica goes even further back to the Macintosh era.

Originally [Kevin] had ordered an authentic Macintosh with the intent of getting it working again, but a broken floppy disk drive and lack of replacement parts turned this project into a different beast. He used the Mac instead as a model for a new 3D-printed case, spending a ton of time sanding, filling, and finishing it to get it to look nearly indistinguishable from the original. The hardware going in this replica is an old Linux-based thin client machine running the Mini vMac operating system, with a modified floppy drive the computer uses to boot. A hidden SD card slot helps interface with modern computers. The display is a modern LCD, though a sheet of acrylic glued to the front panel replicates a bit of the CRT curve.

Click through to read on!

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A portable digital radio transceiver in a 3d printed case

RNODE: A Portable Unrestricted Digital Radio

March 18, 2024 by Dave Rowntree 10 Comments

RNode is an open source, unrestricted digital radio transceiver based on — but not limited to — the Reticulum cryptographic networking stack. It is another interesting project in what we might call the “Federated application” space in that it is intended to be used with no central controlling body. It can be used in a LAN or WAN context with the Reticulum network when operating in network adaptor mode, but it also has other use cases.

Essentially, RNode is a software project running on a LilyGO LoRa32 board wrapped up in a snazzy-looking 3D-printed case. Just make sure to grab a version of the board with an u.FL connector in place or somewhere to solder one. If it comes with an SMA connector, you will want to remove that. The device can be standalone, perhaps attached to a mobile device via Wi-Fi, but it needs to be hooked up to a laptop for the really interesting applications. When set to TNC mode, it can act as an APRS gateway, which allows you to access packet radio BBSs and all that fun stuff.

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TOPS, The DIY Robot Dog, Has Great Moves

March 15, 2024 by Donald Papp 6 Comments

We love [Aaed Musa]’s TOPS (Traverser of Planar Surfaces) which is a robot dog with custom-made actuators. The DIY is very strong with this project, and the 3D-printed parts alone took a whopping three weeks to print!

There’s additional detail on the electronics and design of TOPS in the build log of the project’s Hackaday.io page, so check it out because there are all sorts of nice design details, like the feet being cast with a silicone outer layer for better traction. We’ve previously covered [Aaed]’s DIY robotic actuator design which we’re delighted to see is put to excellent use in the finished robot.

Of course, a robot’s hardware and physical design is only part of the battle. In fact, [Aaed] says the software side of things was probably the biggest overall challenge. It takes a lot of work to make walking happen, and the process has in fact been a huge learning experience. [Aaed] already has plenty of ideas for a potential TOPS V2.

[Aaed]’s website has video tours of all stages of design and construction of TOPS, and there’s a GitHub repository for all the design details. To see it all in action, check out the short video rounding up the finished robot, embedded here just under the page break.

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A vanadium based flow battery made with 3D printed parts

A Vanadium Redox Flow Battery You Can Build

March 9, 2024 by Dave Rowntree 35 Comments

Vanadium flow batteries are an interesting project, with the materials easily obtainable by the DIY hacker. To that effect [Cayrex2] over on YouTube presents their take on a small, self-contained flow battery created with off the shelf parts and a few 3D prints. The video (embedded below) is part 5 of the series, detailing the final construction, charging and discharging processes. The first four parts of the series are part 1, part 2, part 3, and part 4.

The concept of a flow battery is this: rather than storing energy as a chemical change on the electrodes of a cell or in some localised chemical change in an electrolyte layer, flow batteries store energy due to the chemical change of a pair of electrolytes. These are held externally to the cell and connected with a pair of pumps. The capacity of a flow battery depends not upon the electrodes but instead the volume and concentration of the electrolyte, which means, for stationary installations, to increase storage, you need a bigger pair of tanks. There are even 4 MWh containerised flow batteries installed in various locations where the storage of renewable-derived energy needs a buffer to smooth out the power flow. The neat thing about vanadium flow batteries is centred around the versatility of vanadium itself. It can exist in four stable oxidation states so that a flow battery can utilise it for both sides of the reaction cell.

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Micro Jeep Model Kit Is Both Business Card And Portfolio

March 7, 2024 by Donald Papp 11 Comments

When finding work in product design and prototyping, two things are important to have at hand: a business card, and a sample of one’s work. If one can combine those, even better. Make it unique and eye-catching, and you’re really onto something. That seems to have been the idea behind [agepbiz]’s 1:64 scale micro Jeep model kit that serves as an “overcomplicated” business card.

Complete with box and labels in a shrink-wrapped package.

At its heart, the kit is a little print-in-place model kit that looks a lot like larger injection-molded model kits. Completing it is a custom-made box with custom labels, and it’s even shrink-wrapped. The whole thing fits easily in the palm of a hand.

There’s a lot of different tools effectively used to make the whole thing. The model card itself is 3D printed in multiple filament colors, and the box is constructed from carefully glued cardstock. The labels are custom printed, and a craft cutter (which has multiple uses for a hobbyist) takes care of all the precise cutting. It’s an awfully slick presentation, and the contents do not disappoint.

Get a closer look in the video, embedded just below. And if you like what you see, you’re in luck because we’ve seen [agepbiz]’s work before in this mini jet fighter, complete with blister pack.

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