3D Printed Metro Charger Ready For The Wasteland

December 13, 2019 by Tom Nardi 21 Comments

In the video game Metro 2033 and its subsequent sequels, players fight their way through a post-apocalyptic version of Russia using improvised weapons and tools cobbled together from the sort of bits and bobs the survivors of a nuclear war might be able to scavenge from the rubble. One of the most useful devices in the game is known as the “Universal Charger”: a hand-operated dynamo that the player must use periodically recharge their electrical devices.

Being a fan of the series, [Nikola Petrov] wanted to build his own version of the Metro 2033 charger; but rather than going for an exact screen replica, he decided to explore the mechanism itself and see if he could 3D print a functional device.

As demonstrated in the video after the break, his charger manages to produce enough energy to light an LED on each squeeze of the trigger. Though if we were packing our gear to go fight mutated beasties in alternate-future Moscow, we might look for something with a bit more kick.

Beyond the 3D printed parts, the charger uses a couple short pieces of 8 mm rod, a NEMA 17 stepper motor, and a one-way bearing that’s usually used for pull starting small gasolene engines.

Interestingly, [Nikola Petrov] is no stranger to 3D printed electrical generation. If you’re interested in getting some real power out of a NEMA 17 stepper, his fantastic printed wind turbine is a must-see.

Continue reading “3D Printed Metro Charger Ready For The Wasteland” →

An Open Assistive Robotic Arm To Help People Feed Themselves

December 12, 2019 by Gerrit Coetzee 7 Comments

Despite being otherwise capable, not everyone is able to feed themselves. [Julien]’s robot arm project aims to bring this crucial independence back to those people. Assistive devices in this space do exist, but as always they’re prohibitively expensive and the approval process is a nightmare. The development of the arm started by working closely with people who needed it at a local hospital. We note with approval, quite a few cardboard mock-ups to get the size and shape right before more formal work was done in CAD.

The robot arm only has to support a very light payload so its construction can be quite light. A frame of steel rods or plywood is all that’s required. We like how the motion is transferred from stepper motors to the joints of the arm by generously sized timing belts allowing the weight of the arm to remain towards the base. The team behind the project has gotten it to a point, but they’re hoping it will inspire community involvement as they move forward with it.

It’s worth noting, this is not the first assistive eating aid we’ve covered.

Winter Is Coming, This Clock Will Let You Know When

December 2, 2019 by Tom Nardi 1 Comment

For Game of Thrones fans, it’s an awkward time. The show has ended its run on HBO (not without a certain level of controversy), the planned prequel is still years away, and who knows when George R. R. Martin will actually get around to writing the final books in the series. Fans have no choice but to entertain themselves while waiting for further tales of adventure from Westeros, which is how we get things like this motorized clock from [Techarge].

Inspired by the now iconic opening sequence from the HBO series, elements of the 3D printed model spin around while the theme song is played courtesy of a DFPlayer Mini MP3 player module and small 2 watt speaker. The audio hardware, motor, and four digit LED display module in the front are all connected to an Arduino with a custom PCB shield, giving the inside of the clock a very clean and professional appearance.

Around the back side [Techarge] has two small push buttons to set the hour and minutes, and a large toggle to control the music and movement. As of right now it needs to be switched on and off manually, but a future enhancement could see it kick on hourly. We’d also like to see an RTC module added to the PCB, or better yet, switch over to the ESP8266 and just pull the time down from NTP.

Who knows? By the time you’ve built one of these clocks for yourself, and the hand-made Iron Throne phone charger stand to go with it, maybe ol’ George will have slipped out a new book. But don’t count on it.

Improved Outdoor Solar Harvester Now Handles All The Parts

November 19, 2019 by Donald Papp 6 Comments

[Vadim Panov]’s 3D printed solar harvester is in effect a rechargeable outdoor battery, and the real challenge he faced when designing it was having it handle the outdoors reliably. The good news is that part is solved, and his newest design is now also flexible enough to handle a variety of common and economical components such as different battery connectors, charge controllers, and solar panel sizes. All that’s left is to set it up using the GoPro-style mounting clamp and let it soak up those solar rays.

We saw his first version earlier this year, which uses inventive and low-cost solutions for weatherproofing like coating the 3D print with epoxy (the new version makes this easier and less messy, by the way.) It was a fine design, but only worked with one specific solar panel size and one specific configuration of parts. His newest version makes a few mechanical improvements and accommodates a wide variety of different components and solar panel sizes. The CAD files are all available on the GitHub repository but he’s conveniently provided STL files for about a dozen common sizes.

When it comes to harvesting light, staying indoors offers less power but requires a far less rugged setup. If that interests you, be sure to check out the Tiny Solar Energy Module (TSEM) which can scrape up even indoor light.

Needling Your Projects: 3D Printed PCB Probing Jig Uses Accupuncture Needles

November 15, 2019 by Danie Conradie 18 Comments

Trying to probe a modern electronic circuit with tiny SMD components, without letting the magic smoke escape in the process, can be quite a challenge. Especially since we hackers have not yet developed the number of appendages required to hold 3 different probes in place while operating both an oscilloscope and a computer. [Giuseppe Finizia] solved this problem with a 3D printed PCB probing jig that uses acupuncture needles.

As part of [Giuseppe] day job as an engineer at an electronic forensics laboratory, he does technical investigations on seized devices, which involves quite a bit of probing. The jig consists of a base plate with slots in which PCB holders of various configurations slide to hold all shapes and sizes of PCBs. Around the circumference of the plate there are multiple positions for adjustable probing “cranes”, each of which hold an acupuncture needle that is crimped or soldered to a wire. Each needle holder has a bit of flex which allows it to maintain downward pressure for a positive connection.

Making one-off tools and jigs is arguably one of the best applications for 3D printing, of which this is a perfect example. You can of course point solder wires or use test hooks if you have something to grab onto, but for easily probing multiple point on any PCB, this looks like a damn good solution. If you’re trying to trace a single signal, a precision pantograph might be your friend, or you can add a foot switch to your oscilloscope for quickly checking a circuit by hand.

[Jonathon Oxer] from the YouTube channel SuperHouse did a very nice video on the jig and made some small modifications. Check out the video after the break.

Massive 3D-Printed Ridable Tank Boggles The Mind

November 2, 2019 by Danie Conradie 19 Comments

Anyone who has used an FDM 3D printer knows just how long the process can take, especially when you really start filling up the available print volume. Apparently [Ivan Miranda] has absolutely zero fear of insanely long print times, and is in the process of building a massive ridable tank (YouTube playlist of the whole build) that is almost completely 3D printed.

[Ivan] is no stranger to large prints, but this tank is on a different level altogether. The chassis, which is reinforced with aluminium and steel square tubing, took around 1200 hours to print and each of the wheels took 6 days! The rolling chassis with wheels and track weighs close to a 100 kg. Having built a few smaller 3D printed tracked vehicles before, [Ivan] used a lot of that knowledge to design the latest monster.

Connecting the tracked section together has always proven challenging for [Ivan]. This time he used plastic fish tape (wire puller) for the pins, and blocked off the end holes with screws. The bogies (wheel sets) are also interesting, with 3D printed springs that sit parallel to the ground. Almost all the parts are printed in PLA, which can be quite brittle, so it would be interesting to see how it holds up.

[Ivan] has been working on this project since the start of 2019, and we can’t wait to see it completed. We’ve featured his signature red prints a few times, including a RC car that drives on the ceiling and a water jet drive. If you’re keen to build your own tank on the opposite side of the size spectrum, check out this tiny tank for your crawl space. Watch [Ivan] finish the rolling chassis after the break. Continue reading “Massive 3D-Printed Ridable Tank Boggles The Mind” →

Robot Joints Go Modular With This Actuator Project

October 22, 2019 by Donald Papp 4 Comments

[John Lauer] has been hard at work re-thinking robot arms. His project to create modular, open source actuators that can be connected to one another to form an arm is inspiring, and boasts an impressively low parts cost as well. The actuators are each self-contained, with an ESP32 and a design that takes advantage of the form factors of inexpensive modules and parts from vendors like Aliexpress.

Flex spline in action, for reducing backlash

Each module has 3D printed gears (with an anti-backlash flex spline), an RGB LED for feedback, integrated homing, active cooling, a slip ring made from copper tape, and a touch sensor dial on the back for jogging and training input. The result is a low backlash, low cost actuator that keeps external wiring to an absolute minimum.

Originally inspired by a design named WE-R2.4, [John] has added his own twist in numerous ways, which are best summarized in the video embedded below. That video is number three in a series, and covers the most interesting developments and design changes while giving an excellent overview of the parts and operation (the video for part one is a basic overview and part two shows the prototyping process, during which [John] 3D printed the structural parts and gears and mills out a custom PCB.)

Continue reading “Robot Joints Go Modular With This Actuator Project” →