One-key Keyboard Is Exercise In Sub-millimeter Design

May 19, 2018 by Donald Papp 15 Comments

As [Glen] describes it, the only real goal in his decision to design his single-key USB keyboard was to see how small he could build a functional keyboard using a Cherry MX key switch, and every fraction of a millimeter counted. Making a one-key USB keyboard is one thing, but making it from scratch complete with form-fitting enclosure that’s easy to assemble required careful design, and luckily for all of us, [Glen] has documented it wonderfully. (Incidentally, Cherry MX switches come in a variety of qualities and features, the different models being identified by their color. [Glen] is using a Cherry MX Blue, common in keyboards due to its tactile bump and audible click.)

[Glen] steps though the design challenges of making a device where seemingly every detail counts, and explains problems and solutions from beginning to end. A PIC16F1459, a USB micro-B connector, and three capacitors are all that’s needed to implement USB 2.0, but a few other components including LED were added to help things along. The enclosure took some extra care, because not only is it necessary to fit the board and the mounted components, but other design considerations needed to be addressed such as the depth and angle of the countersink for the screws, seating depth and clearance around the USB connector, and taking into account the height of the overmold on the USB cable itself so that the small device actually rests on the enclosure, and not on any part of the cable’s molding. To top it off, it was also necessary to adhere to the some design rules for minimum feature size and wall thicknesses for the enclosure itself, which was SLS 3D printed in nylon.

PCB, enclosure, software, and bill of materials (for single and triple-key versions of the keyboard) are all documented and available in the project’s GitHub repository. [Glen] also highlights the possibility of using a light pipe to redirect the embedded LED to somewhere else on the enclosure; which recalls his earlier work in using 3D printing to make custom LED bar graphs.

Fail Of The Week: 3D Printed Worm Gear Drive Project Unveils Invisible Flaw

May 11, 2018 by Roger Cheng 27 Comments

All of us would love to bring our projects to life while spending less money doing so. Sometimes our bargain hunting pays off, sometimes not. Many of us would just shrug at a failure and move on, but that is not [Mark Rehorst]’s style. He tried to build a Z-axis drive for his 3D printer around an inexpensive worm gear from AliExpress. This project was doomed by a gear flaw invisible to the human eye, but he documented the experience so we could all follow along.

We’ve featured [Mark]’s projects for his ever-evolving printer before, because we love reading his well-documented upgrade adventures. He’s not shy about exploring ideas that run against 3D printer conventions, from using belts to drive the Z-axis to moving print cooling fan off the print head (with followup). And lucky for us, he’s not shy about document his failures alongside the successes.

He walks us through the project, starting from initial motivation, moving on to parts selection, and describes how he designed his gearbox parts to work around weaknesses inherent to 3D printing. After the gearbox was installed, the resulting print came out flawed. Each of the regularly spaced print bulge can be directly correlated to a single turn of the worm gear making it the prime suspect. Then, to verify this observation more rigorously, Z-axis movement was measured with an indicator and plotted against desired movement. If the problem was caused by a piece of debris or surface damage, that would create a sharp bump in the plot. The sinusoidal plot tells us the problem is more fundamental than that.

This particular worm gear provided enough lifting power to move the print bed by multiplying motor torque, but it also multiplied flaws rendering it unsuitable for precisely positioning a 3D printer’s Z-axis. [Mark] plans to revisit the idea when he could find a source for better worm gears, and when he does we’ll certainly have the chance to read what happens.

Gorgeous NickelBot Serves Up Lasered Wooden Nickels

May 9, 2018 by Donald Papp 22 Comments

[bdring] just recently completed his absolutely fantastic NickelBot, which is a beautifully made unit that engraves small wooden discs with a laser like some kind of on demand vending machine, and it’s wonderful. NickelBot is small, but a lot is going on inside. For example, there’s a custom-designed combination engraving platform and hopper that takes care of loading a wooden nickel from a stack, holding it firm while it gets engraved by a laser, then ejects it out a slot once it’s done.

NickelBot is portable and can crank out an engraved nickel within a couple of minutes, nicely fulfilling its role of being able to dish out the small items on demand at events while looking great at the same time. NickelBot’s guts are built around a PSoC5 development board, and LaserGRBL is used on the software side to generate G-code for the engraving itself. Watch it work in the video embedded below.

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Home Made 5-Axis CNC Head Is A Project To Watch

April 20, 2018 by Richard Baguley 52 Comments

[Reiner Schmidt] was tired of renting an expensive 5-axis CNC head for projects, so he decided to build his own. It’s still a work in progress, but he’s made remarkable progress so far. The project is called Bridge Boy, and it is designed to use a cheap DC rotary mill to cut soft materials like plastic, wood and the like. Most of it is 3D printed, and he has released the Autodesk 360 plans that would allow you to start building your own. His initial version uses an Arduino with stepper drivers, and is designed to fit onto the end of a 60mm arm of a standard 3-axis CNC, so technically it’s a 3+2 axis CNC. With the appropriate software, it should be able to work as a full 5-axis machine, though, and it should be possible to integrate it with a CNC that has a 5-axis driver board without too much effort.

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DIY Magnetic Actuator, Illustrated And Demonstrated

April 17, 2018 by Donald Papp 11 Comments

Electromagnetic actuators exert small amounts of force, but are simple and definitely have their niche. [SeanHodgins] took a design that’s common in flip-dot displays as well as the lightweight RC aircraft world and decided to make his own version. He does a good job of explaining and demonstrating the basic principles behind how one of these actuators works, although the “robotic” application claimed is less clear.

It’s a small, 3D printed lever with an embedded magnet that flips one way or another depending on the direction of current flowing through a nearby coil. Actuators of this design are capable of fast response and have no moving parts beyond the lever itself, meaning that they can be made very small. He has details on an imgur gallery as well as a video, embedded below.

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Customize All The Fan Covers You Never Knew You Needed

April 13, 2018 by Donald Papp 11 Comments

Do you need a fancy fan cover with precisely specified attributes, but have no desire to design one from scratch? If you answered yes (or no) then [mightynozzle] has the answer. The Customizable Fan Grill Cover is a parametric design in OpenSCAD that allows adjusting the frame style, size, and grill pattern for any fan cover one may possibly need. [mightynozzle] also went the extra mile to provide a large number of pre-made STL files for a variety of designs in a wide range of sizes, so those who don’t want to fuss with customizing can simply download and print.

Normally Thingiverse would allow customizing this model’s attributes with their built-in Customizer, but the functionality and availability of that feature is spotty. Luckily it’s always an option to download the source and do the customizing directly in OpenSCAD. For those who may be intrigued but are not sure where to start, here’s a reminder that we covered how to make a thing with OpenSCAD that demonstrates the whole process.

Art Deco Radio Gets FM Reception

April 7, 2018 by Tom Nardi 12 Comments

Taking a vintage radio and cramming it full of modern, Internet-connected, guts has long been a staple of the hacking and making scene. While some might see it as a crime to take what’s arguably a legitimate piece of history and turn it into nothing more than a slipshod case for the Raspberry Pi, we have to admit there’s a certain appeal to the idea. Taking the beauty of classic design and pairing it with more modern capabilities is getting the best of both worlds.

But this project by [Nick Koumaris] is a somewhat unique take on the concept. Rather than sacrificing a real vintage piece of hardware to house the electronics, he’s designed a 3D printable case that looks like a classic 1936 AWA Radiolette. But what’s really interesting to us is that he then puts a basic FM radio inside of it.

That’s right, no Internet radio streaming or smartphone Bluetooth compatibility here. It’s just a regular FM radio, not entirely unlike the kind of hardware you’d expect to be inside of a classic radio. Of course, it’s much more modern, and [Nick] actually built it himself from a TEA5767 FM radio module and an Arduino Pro Mini.

While functionally it might not be terribly exciting, we do appreciate that he went through the trouble to make a vintage-looking user interface for the radio. While physical buttons would arguably have been more appropriate given the era, the art deco inspired font and graphics that show on the device’s Nokia 5110 LCD do look really slick.

Purists will surely be happy to see another project where a piece of vintage piece of audio equipment wasn’t sacrificed at the Altar of Hack, but we’ve also played host to many projects which weren’t nearly as concerned with historical preservation.

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