How To Build Anything Out Of Aluminum Extrusion And 3D Printed Brackets

May 8, 2018 by Roger Cheng 42 Comments

The real power of 3D printing is in infinite customization of parts. This becomes especially powerful when you combine 3D printing with existing materials. I have been developing a few simple tricks to make generic fasteners and printed connectors a perfect match for aluminum extrusion, via a novel twist or two on top of techniques you may already know.

Work long enough with 3D printers, and our ideas inevitably grow beyond our print volume. Depending on the nature of the project, it may be possible to divide into pieces then glue them together. But usually a larger project also places higher structural demands ill-suited to plastic.

Those of us lucky enough to have nice workshops can turn to woodworking, welding, or metal machining for larger projects. Whether you have that option or not, aluminum extrusion beams provide the structure we need to go bigger and to do it quickly. And as an added bonus, 3D printing can make using aluminum extrusion easier and cheaper.

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The Aluminum Wiring Fiasco

May 7, 2018 by Dan Maloney 141 Comments

Someone who decides to build a house faces a daunting task. It’s hard enough to act as the general contractor for someone else, but when you decide to build your own house, as my parents did in the early 1970s, it’s even tougher. There are a million decisions to make in an information-poor and rapidly changing environment, and one wrong step can literally cast in stone something you’ll have to live with forever. Add in the shoestring budget that my folks had to work with, and it’s a wonder they were able to succeed as well as they did.

It was a close call in a few spots, though. I can recall my dad agonizing over the wiring for the house. It would have been far cheaper to go with aluminum wiring, with the price of copper wire having recently skyrocketed. He bit the bullet and had the electrician install copper instead, which ended up being a wise choice, as houses that had succumbed to the siren call of cheaper wiring would start burning down all over the United States soon thereafter.

What happened in the late 60s and early 70s in the residential and commercial electrical trades was an expensive and in some cases tragic lesson in failure engineering. Let’s take a look at how it all happened.

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This Vapour Deposition Chamber Isn’t Vapourware

April 20, 2018 by Jenny List 22 Comments

If you are an astronomer with an optical reflecting telescope, the quality of your mirror is one of your most significant concerns. Large observatories will therefore often have on-site vapour deposition plants to revitalise their reflectors by depositing a fresh layer of aluminium upon them. You might think that such a device would be the preserve only of such well-funded sites, but perhaps [Michael Koch]’s work will prove you wrong. He’s created his own vapour deposition system (Google Translate link of the German original) from scratch, and while it might be smaller than the institutional equivalents it is no less effective in its task.

At the heart of it is a stainless steel vacuum vessel with a two stage vacuum pump system to evacuate it. The mirror to be silvered is suspended in the vessel, and a piece of aluminium is suspended over a coil of tungsten wire that his electrically heated to melt it. The molten aluminium is described as “wetting” the tungsten wire in the same manner as we’ll be used to solder working on copper, but in the vacuum it vaporizes and deposits itself upon the mirror. Such a simple description glosses over the impressive work that went into it.

This is a long-running project that isn’t entirely new, but very much worth a look if only for its introduction to this fascinating field. If you are new to vacuum work, how about looking at a Superconference presentation introducing vacuum technology?

Thanks [Paul Bauer] for the tip.

Medium Machine Mediates Microcontroller Messages

April 16, 2018 by Brian McEvoy 12 Comments

Connecting computers to human brains is currently limited to the scope of science fiction and a few cutting-edge laboratories. Tapping into some nerves farther from our central wetware is possible and [Peter Buczkowski] shows us his stylish machine for implanting a pattern into our brains without actively having to memorize anything.

His Medium Machine leverages a TENS unit to activate forearm muscles in a pattern programmed into an Arduino. Users place their forearm across two aluminum electrodes mounted on a tasteful wooden platform and extend a single finger over a button. Electrical impulses trigger the muscles which press the button. That’s all. After repeating the pattern a few times, the users should be able to recite it back on command even if they aren’t aware of what it means. If this sounds like some [Johnny Mnemonic] memory cache, you are absolutely correct. This project draws inspiration from the [William Gibson] novel which became a [Keanu Reeves] movie.

Users can be programmed with a Morse code message or the secret knock to open an attic library or play a little tune. How about learning a piano song?

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What’s The Deal With Transparent Aluminum?

April 3, 2018 by Dan Maloney 139 Comments

It looks like a tube made of glass but it’s actually aluminum. Well, aluminum with an asterisk beside it — this is not elemental aluminum but rather a material made using it.

We got onto the buzz about “transparent aluminum” as a result of a Tweet from whence the image above came. This Tweet was posted by [Jo Pitesky], a Science Systems Engineer at the Jet Propulsion Lab in Pasadena. [Jo] reported that at a recent JPL technology open house she had the chance to handle a tube of material that looks for all the world like a section of glass tubing, but was billed as transparent aluminum. [Jo] tweeted this because it was an interesting artifact that few people get to play with and she’s right, this is fascinating!

The the material itself is intriguing, and I immediately had practical questions like what is this stuff? What is it good for? How is it made? And is it really aluminum rendered transparent by some science fiction process?

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Robotic Arm Rivals Industrial Counterparts

November 8, 2017 by Brian McEvoy 21 Comments

We’ve seen industrial robotic arms in real life. We’ve seen them in classrooms and factories. Before today, we’ve never mistaken a homemade robotic arm for one of the price-of-a-new-home robotic arms. Today, [Chris Annin] made us look twice when we watched the video of his six-axis robotic arm. Most of the DIY arms have a personal flare from their creator so we have to assume [Chris Annin] is either a robot himself or he intended to build a very clean-looking arm when he started.

He puts it through its paces in the video, available after the break, by starting with some stretches, weight-lifting, then following it up and a game of Jenga. After a hard day, we see the arm helping in the kitchen and even cracking open a cold one. At the ten-minute mark, [Chris Annin] walks us through the major components and talks about where to find many, many more details about the arm.

Many of the robotic arms on Hackaday are here by virtue of resourcefulness, creativity or unusual implementation but this one is here because of its similarity to the big boys.

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3D Printing Aluminum With Nanoparticles

September 25, 2017 by Al Williams 20 Comments

We love our 3D printers. But sometimes we really wish we could print in metal. While metal printing is still out of reach for most of us, HRL Labs announced a powdered aluminum printing process that they claim is a breakthrough because it allows printing (and welding) of high-strength aluminum alloys that previously were unprintable and unweldable.

The key is treating the metal with special zirconium-based nanoparticles. The nanoparticles act as nucleation sites that allow the aluminum to form the correct microstructure. The full paper on the process appears in Nature.

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