Secret Ingredient For 3D-Printed Circuit Traces: Electroplating

December 6, 2021 by Donald Papp 46 Comments

Conductive filament exists, but it takes more than that to 3D print something like a circuit board. The main issue is that traces made from conductive filament are basically resistors; they don’t act like wires. [hobochild]’s interesting way around this problem is to use electroplating to coat 3D-printed traces with metal, therefore creating a kind of 3D-printed circuit board. [hobochild] doesn’t yet have a lot of nitty-gritty detail to share, but his process seems fairly clear. (Update: good news! here’s the project page and GitHub repository with more detail.)

The usual problem with electroplating is that the object to be coated needs to be conductive. [hobochild] addresses this by using two different materials to create his test board. The base layer is printed in regular (non-conductive) plastic, and the board’s extra-thick traces are printed in conductive filament. Electroplating takes care of coating the conductive traces, resulting in a pretty good-looking 3D-printed circuit board whose conductors feature actual metal. [hobochild] used conductive filament from Proto-pasta and the board is a proof-of-concept flashing LED circuit. Soldering might be a challenge given the fact that the underlying material is still plastic, but the dual-material print is an interesting angle that even allows for plated vias and through-holes.

We have seen conductive filament used to successfully print workable electrical connections, but applications are limited due to the nature of the filament. Electroplating, a technology accessible to virtually every hacker’s workbench, continues to be applied to 3D printing in interesting ways and might be a way around these limitations.

Shady Air Umbrella Given New Lease On Life

December 4, 2021 by Matthew Carlson 12 Comments

Many infamous Kickstarter projects have ultimately flopped or failed, leaving backers frustrated and angry. Often pitched with a splashy convincing video that happens to have critical components conveniently offscreen. [Allen Pan] was reminiscing about one such project, the air umbrella, and decide to redeem the project by making his own.

The basic idea of the air umbrella was a device that could create a cone of fast-moving air over your head to deflect air. Going off of the specs listed on the original Kickstarter page, [Allen] made a simple prototype that did nothing. Suspicions confirmed, he decided to keep going by buying a powerful electric leaf blower. A nozzle was 3d printed that could direct the air into the needed disc. Early testing with the mist function on a garden hose seemed promising, and they worked their way up to progressively larger raindrops.

Finally, the clouds of California smiled upon them, and it rained. [Allen] was ecstatic that his umbrella worked. He couldn’t hear much out of one ear as he was holding a leaf blower next to it for a few minutes, but it’s a small price to pay to stay dry with the Air Umbrella.

If you’re curious about more false Kickstarter claims, why not read up on this tiny Arduino compatible board making some dubious claims.

[Header image courtesy of Air Umbrella Kickstarter page]

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Smart Ruler Has Many Features

December 2, 2021 by Bryan Cockfield 12 Comments

For those of us who remember old ball mice, they were a lot like modern optical mice except that they needed to be cleaned constantly. Having optical mice as a standard way of interacting with a computer is a major improvement over previous eras in computing. With extinction of the ball mouse, there are an uncountable number of cheap optical mice around now which are easy pickings for modern hacking, and this latest project from [Vipul] shows off some of the ways that optical mice can be repurposed by building a digital ruler.

The build seems straightforward on the surface. As the ruler is passed over a surface the device keeps track of exactly how far it has moved, making it an effective and very accurate ruler. To built it, the optical component of a mouse was scavenged and mated directly to a Raspberry Pi Zero W over USB. Originally he intended to use an ESP32 but could not get the USB interface to work. [Vipul] was then able to write some software which can read the information from the mouse’s PCB directly and translate it into human-readable form where it is displayed on a small screen. The entire device is housed in a custom 3D-printed enclosure to wrap everything up, but the build doesn’t stop there though. [Vipul] also leveraged the Bluetooth functionality of the Pi and wrote a smartphone app which can be used to control the ruler as well.

While the device does have some limitations in that it has to make contact with the object being measured across its entire length, there are some situations where we can imagine something like this being extremely useful especially when measuring things that aren’t a straight line. [Vipul] has also made all of the code for this project publicly available for those of us who might have other uses in mind for something like this. We’ve seen optical mice repurposed for all kinds of things in the past, too, including measuring travel distances in autonomous vehicles.

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Generate Fully Parametric, 3D-Printable Speaker Enclosures

November 28, 2021 by Donald Papp 9 Comments

Having the right speaker enclosure can make a big difference to sound quality, so it’s no surprise that customizable ones are a common project for those who treat sound seriously. In that vein, [zx82net]’s Universal Speaker Box aims to give one everything they need to craft the perfect enclosure.

The parts can be 3D-printed, but the design ensures that the front and back panels are flat, so one can use wood or some other material for those depending on preference and appearance. The assembly is screwed together using six M3 bolts per side with optional heat-set inserts, but it’s entirely possible to simply glue the unit together if preferred.

One thing that makes this design a bit more broadly useful is that [zx82net] not only provides the parametric design file for Fusion360, but also includes STEP format CAD files, and a small number of pre-configured assemblies for a few commonly available speaker drivers: the Dayton Audio DMA70-4, ND91-4, and the TCP115-4. Not enough for you? Check out [zx82net]’s collection of ready-to-rock enclosures in a variety of designs and configurations; there’s bound to be something to appeal to just about anyone.

[via Reddit]

Indoor Blimp Sails Through The Air Using Ultrasonic Transducers

November 27, 2021 by Dave Rowntree 25 Comments

Quadcopter type drones can be flown indoors, but unless you have a lot of space, it usually just ends in a crash. The prospect of being hit in the face by the propellor blades, spinning at 10k RPM doesn’t bear thinking about, and then there’s the noise. So, as a solution for indoor photography, or operating in public spaces, they are not viable. Japanese mobile operator DOCOMO has a new take on an old idea; the blimp. But, surely even a helium filled vehicle needs blades to steer around the room, we hear you cry? Not so, if you use a pair of specialised ultrasonic transducer arrays to move the air instead! (Video, embedded below)

Three banks of thrusters provide a 180 degree steerable net force

Details are scarce, but DOCOMO have fitted a helium balloon with modules on either side that can produce a steerable thrust, allowing the vehicle to effect all the expected aerial manoeuvres with ease and grace. The module at the bottom contains the control electronics, an upwards facing RGB LED for some extra bling, and of course a video camera to capture those all-important video shots.

We’d love to find a source for those ultrasonic transducer devices, and can only guess at the physical arrangement that allows for air to pass in one direction only, to effect a net thrust. We can find a few research papers hinting at the ability to use ultrasound to propel through air, like this one (bah! IEEExplore Paywall!) but to our knowledge, this technology is not quite in the hands of hackers just yet.

Blimps are by no means scarce on these fine pages, here is a Blimpduino, an Arduino controlled 3D printed blimp, an illuminated blimp art installation by Japanese artist [Kensho Miyoshi] and if using helium is just too darn safe for you (or if you want to help prevent this allegedly precious resource from being lost into space) you could just build a remote controlled blimp using hydrogen instead. Just don’t light a match.

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Surfboard Gets Jet Upgrades

November 25, 2021 by Bryan Cockfield 6 Comments

Surfing is a fun and exciting sport but a lot of beginners can get discouraged with how little time is spent actually riding waves while learning. Not only are balance and wave selection critical skills that take time to learn, but a majority of time in the water is spent battling crashing waves to get out past the breakers. Many people have attempted to solve this problem through other means than willpower alone, and one of the latest attempts is [Andrew W] with a completely DIY surfboard with custom impeller jet drives.

The surfboard is hand-made by [Andrew W] himself using a few blocks of styrofoam glued together and then cut into a generic surfboard shape. After the rough shaping is done, he cuts out a huge hole in the back of the board for the jet drive. This drive is almost completely built by [Andrew] as well including the impeller pumps themselves which he designed and 3D printed. The pair of impellers are driven by some beefy motors and a robust speed controller that connects wirelessly to a handheld waterproof throttle to hold while surfing. Once everything was secured in the motor box the surfboard was given a final shaping and then glassed. The final touch was an emergency disconnect attached to a leash so that if he falls off the board it doesn’t speed away without him.

The build is impressive not only for [Andrew]’s shaping skills but for his dedication to a custom jet drive for the surfboard. He spent over a year refining the build and actually encourages people not to do this as he thinks it took too much time and effort, but we’re going to have to disagree with him there. Even if you want to try to build something a lot simpler, builds like these look like a lot of fun once they’re finished. The build seems flawless and while he only tested it in a lake we’re excited to see if it holds up surfing real waves in an ocean.

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E-MonoWheel

November 24, 2021 by Matthew Carlson 16 Comments

Generally, monowheels are that wacky, wildly futuristic transport that we lump in the same category as hoverbikes and jetpacks: strange, currently impractical, but very cool. Not content with waiting for the distant future, [Sam Barker] made his own electric monowheel. (Video, embedded below.)

The hardest part of any monowheel is that the outside rim needs to stand enormous abuse. It supports the weight of the vehicle and provides most of the structural integrity, but also is the means of propulsion. [Sam]’s first thought was to use a trampoline frame as it is a round and reasonably sturdy tube steel. He 3D printed the rollers that connected the subframe to the trampoline frame. Flat bar stock was used to make the angles inside the subframe and straight tube steel connected the inner frame into a trapezoid. The trampoline frame was welded together and on the first test spin, it broke apart from the stress. It simply wasn’t strong enough.

Not to be dissuaded, he found a company that bends steel into custom shapes. He stole the e-bike kit from another bike he had converted earlier, and the wheel was turning. Some handles and foot-pedal later, it was time for a proper test drive. Overall, the result is pretty impressive and the double-takes [Sam] gets while riding down streets in town are wonderful. If you’re looking to scratch the monowheel itch, check out this wooden monowheel.

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