Arduino PLC Keeps The Beat

July 6, 2024 by Bryan Cockfield 12 Comments

For most of our prototype, hobby, or one-off electronics projects it’s perfectly fine to use a development platform like an Arduino Uno or something to that effect. They’re both easy to program and easy to wire up to projects without breaking the bank. But if you step into an industrial setting where reliability is paramount even in places that are noisy, vibrating all the time, hot, or otherwise unpleasant for electronics, you’ll want to reach for a programmable logic controller (PLC) that are much more robust. There is actually a PLC from Arduino, and if you want to dip your toes into the PLC world then take a look at this drum kit based on the Arduino Opta.

With the PLC at the core of the build, it’s on to making the drumming mechanisms themselves. For that, project creator [JC Audio] is using a series of solenoids attached to camera mounts with a custom 3D printed part that allows for quick assembly and disassembly so he can get the positioning of each drum sound just right. The high hat is taken care of by the noise of an internal solenoid, with the other drums striking various real drums and other solid objects in his shops. The solenoids themselves are driven by a solid-state relay expansion module to ensure there’s enough power

While the build doesn’t sit inside a factory and run for years at a time, a musician’s stage is certainly a rough enough environment that we might reach for a PLC over a standard development board for its benefits. The code for this project is available as well at the project’s GitHub page for those looking for a more advanced timekeeper to play along with their music practice, and for more details on why you might choose a PLC for your project take a look at this Arduino vs PLC showdown from a few years ago.

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An Easy Transparent Edge Lit Display

June 24, 2024 by Dave Rowntree 20 Comments

Displays are crucial to modern life; they are literally everywhere. But modern flat-panel LCDs and cheap 7-segment LED displays are, well, a bit boring. When we hackers want to display the progress of time, we want something more interesting, hence the plethora of projects using Nixie tubes and various incantations of edge-lit segmented units. Here is [upir] with their take on the simple edge-lit acrylic 7-segment design, with a great video explanation of all the steps involved.

Engraving the acrylic sheets by hand using 3D printed stencils

The idea behind this concept is not new. Older displays of this type used tiny tungsten filament bulbs and complex light paths to direct light to the front of the display. The modern version, however, uses edge-lit panels with a grid of small LEDs beneath each segment, which are concealed within a casing. This design relies on the principle of total internal reflection, created by the contrast in refractive indices of acrylic and air. Light entering the panel from below at an angle greater than 42 degrees from normal is entirely reflected inside the panel. Fortunately, tiny LEDs have a wide dispersion angle, so if they are positioned close enough to the edge, they can guide sufficient light into the panel. Once this setup is in place, the surface can be etched or engraved using a CNC machine or a laser cutter. A rough surface texture is vital for this process, as it disrupts some of the light paths, scattering and directing some of it sideways to the viewer. Finally, to create your display, design enough parallel-stacked sheets for each segment of the display—seven in this case, but you could add more, such as an eighth for a decimal point.

How you arrange your lighting is up to you, but [upir] uses an off-the-shelf ESP32-S3 addressable LED array. This design has a few shortcomings, but it is a great start—if a little overkill for a single digit! Using some straightforward Arduino code, one display row is set to white to guide light into a single-segment sheet. To form a complete digital, you illuminate the appropriate combination of sheets. To engrave the sheets, [upir] wanted to use a laser cutter but was put off by the cost. A CNC 3018 was considered, but the choice was bewildering, so they just went with a hand-engraving pick, using a couple of 3D printed stencils as a guide. A sheet holder and light masking arrangement were created in Fusion 360, which was extended into a box to enclose the LED array, which could then be 3D printed.

If you fancy an edge-lit clock (you know you do) check out this one. If wearables are more your thing, there’s also this one. Finally, etched acrylic isn’t anywhere near as good as glass, so if you’ve got a vinyl cutter to hand, this simple method is an option.

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Watch SLS 3D Printed Parts Become Printed Circuits

June 20, 2024 by Donald Papp 38 Comments

[Ben Krasnow] of the Applied Science channel recently released a video demonstrating his process for getting copper-plated traces reliably embedded into sintered nylon powder (SLS) 3D printed parts, and shows off a variety of small test boards with traces for functional circuits embedded directly into them.

Here’s how it works: The SLS 3D printer uses a laser to fuse powdered nylon together layer by layer to make a plastic part. But to the nylon powder, [Ben] has added a small amount of a specific catalyst (copper chromite), so that prints contains this catalyst. Copper chromite is pretty much inert until it gets hit by a laser, but not the same kind of laser that sinters the nylon powder. That means after the object is 3D printed, the object is mostly nylon with a small amount of (inert) copper chromite mixed in. That sets the stage for what comes next.

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RC Batwing Actually Flies

June 16, 2024 by Bryan Cockfield 8 Comments

Batman is a compelling superhero for enough reasons that he’s been a cultural force for the better part of a century. His story has complex characters, interesting explorations of morality, iconic villains, and of course a human superhero who gets his powers from ingenuity instead of a fantastical magical force. There are a number features of the Batman universe that don’t translate well to the real world, though, such as a costume that would likely be a hindrance in fights, technology that violates the laws of physics, and a billionaire that cares about regular people, but surprisingly enough his legendary Batwing jet airplane actually seems like it might be able to fly.

While this is admittedly a model plane, it flies surprisingly well for its nontraditional shape. [hotlapkyle] crafted it using mostly 3D printed parts, and although it took a few tries to get it working to his standards, now shoots through the air quite well. It uses an internal electric ducted fan (EDF) to get a high amount of thrust, and has elevons for control. There are two small vertical stabilizer fins which not only complete the look, but allow the Batwing to take to the skies without the need for a flight controller.

Not only is the build process documented in the video linked below with some interesting tips about building RC aircraft in general, but the STL files for this specific build are available for anyone wanting to duplicate the build or expand on it. There are plenty of other interesting 3D-printed models on [hotlapkyle]’s page as well that push the envelope of model aircraft. For some other niche RC aircraft designs we’ve seen in the past be sure to check out this F-35 model that can hover or this tilt-rotor Osprey proof-of-concept.

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BikeBeamer Adds POV Display To Bicycle Wheels

June 11, 2024 by Bryan Cockfield 16 Comments

Unless you’re living in a bicycle paradise like the Netherlands, most people will choose to add some sort of illumination to their bicycle to help drivers take note that there’s something other than a car using the road. Generally, simple flashing LEDs for both the front and the rear is a pretty good start, but it doesn’t hurt to add a few more lights to the bicycle or increase their brightness. On the other hand, if you want to add some style to your bicycle lighting system then this persistence of vision (POV) display called the BikeBeamer from [locxter] might be just the thing.

The display uses four LED strips, each housed in their own 3D printed case which are installed at 90-degree angles from one another in between the spokes of a standard bicycle wheel. An ESP32 sits at the base of one of the strips and is responsible for storing the image and directing the four displays. This is a little more complex than a standard POV display as it’s also capable of keeping up with the changing rotational speeds of the bicycle wheels when in use. The design also incorporates batteries so that no wires need to route from the bike frame to the spinning wheels.

This is an ongoing project for [locxter] as well, meaning that there are some planned upgrades even to this model that should be in the pipe for the future. Improving the efficiency of the code will hopefully allow for more complex images and even animations to be displayed in the future, and there are also some plans to improve the PCB as well with all surface-mount components. There are a few other ways to upgrade your bike’s lighting as well, and we could recommend this heads-up headlight display to get started.

Automating 3D Printer Support Hardware

June 6, 2024 by Bryan Cockfield 22 Comments

While 3D printers have evolved over the past two decades from novelties to powerful prototyping tools, the amount of support systems have advanced tremendously as well. From rudimentary software that required extensive manual input and offered limited design capabilities, there’s now user-friendly interfaces with more features than you could shake a stick at. Hardware support has become refined as well with plenty of options including lighting, ventilation, filament recycling, and tool changers. It’s possible to automate some of these subsystems as well like [Caelestis Workshop] has done with this relay control box.

This build specifically focuses on automating or remotely controlling the power, enclosure lighting, and the ventilation system of [Caelestis Workshop]’s 3D printer but was specifically designed to be scalable and support adding other features quickly. A large power supply is housed inside of a 3D printed enclosure along with a Raspberry Pi. The Pi controls four relays which are used to control these various pieces hardware along with the 3D printer. That’s not the only thing the Pi is responsible for, though. It’s also configured to run Octoprint, a piece of open-source software that adds web interfaces for 3D printers and allows their operation to be monitored and controlled remotely too.

With this setup properly configured, [Caelestis Workshop] can access their printer from essentially any PC, monitor their prints, and ensure that ventilation is running. Streamlining the print process is key to reducing the frustration of any 3D printer setup, and this build will go a long way to achieving a more stress-free environment. In case you missed it, we recently hosed a FLOSS Weekly episode talking about Octoprint itself which is worth a listen especially if you haven’t tried this piece of software out yet.

Make A Super Cute LiDAR Measurement Module

June 2, 2024 by Donald Papp 10 Comments

This ultra-cute tiny LiDAR rangefinder project by [gokux] can be thought of as a love letter to the incredible resources and components hobbyists and hackers of all types have access to nowadays. In fact, it all stemmed from coming across a miniscule half-inch 64×32 OLED display module that was simply too slick to pass up.

USB connector for charging on the bottom, hole for distance sensor out the top.

To use it, one simply powers it on and the display will read out the distance in millimeters. The VL53L0X time-of-flight sensor inside works by sending out a laser pulse and measuring how long it takes for the pulse to bounce back. We hope you’re curious about what such a sensor looks like on the inside, because here’s a nifty teardown of these fantastic devices. The device can technically measure distances of up to 2 m, but [gokux] says accuracy drops off after 1 m.

The main components besides the OLED display and VL53L0X sensor are an ESP32-C3 board (which handily integrates battery charging circuitry), 3D-printed enclosure, tiny rechargeable battery, and power switch. The whole thing is under one cubic inch. Not bad, and it even makes a passable keychain. Parts list, code, and 3D model files, including STEP format, are all available if you’d like to spend an afternoon making your own.