Prevent Failed Prints With A Filament Speed Sensor

June 16, 2015 by Ethan Zonca 41 Comments

If you have used a 3D printer for any length of time, you’ve probably experienced a failed print caused by a clogged nozzle. If you’re not around to stop the print and the nozzle stays hot and full of filament for hours, the clog gets even worse. [Florian] set out to solve this issue with an encoder that measures filament speed, which acts as an early warning system for nozzle clogs.

[Florian] designed a small assembly with a wheel and encoder that measures filament movement. The filament passes under the encoder wheel before it’s fed into the 3D printer. The encoder is hooked up to an Arduino which measures the Gray code pulses as the encoder rotates, and the encoder count is streamed over the serial port to a computer.

When the filament slows down or stops due to a nozzle clog, the Python script plays a notification sound to let you know that you should check your nozzle and that your print might fail. Once [Florian] works out some of the kinks in his setup, it would be awesome if the script could stop the print when the nozzle fails. Have any other ideas on how to detect print failures? Let us know in the comments.

Two New Dev Boards That Won’t Make Your Wallet Hurt-So-Good

June 13, 2015 by Sonya Vasquez 48 Comments

If you’ve been keeping up with the hobbyist FPGA community, you’ll recognize the DE0 Nano as “that small form-factor FPGA” with a deep history of projects from Oldland cpu cores to synthesizable Parallax Propeller processors. After more than four years in the field though, it’s about time for a reboot.

Its successor, the DE0 Nano SoC, is a complete redesign from multiples perspectives while doing it’s best to preserve the bite-size form factor and price that made the first model so appealing. First, the dev board boasts a Cyclone V with 40,000 logical elements (up from the DE0’s 22K) and an integrated dual-core Arm Cortex A9 Processor. The PCB layout also brings us 3.3V Arduino shield compatibility via female headers, 1 Gig of external DDR3 SDRAM and gigabit ethernet support via two onboard ASICs to handle the protocol. The folks at Terasic also seem to be tipping their hats towards the “Duino-Pi” hobbyist community, given that they’ve kindly provided both Linux and Arduino images to get you started a few steps above your classic finite-state machines and everyday combinational logic.

And while the new SoC model sports a slightly larger form factor at 68.59mm x 96mm (as opposed to the original’s 49mm x 75.2mm), we’d say it’s a small price to pay in footprint for a whirlwind of new possibilities on the logic level. The board hits online shelves now at a respectable $100.

Next, as a heads-up, the aforementioned Arduino Zero finally makes it’s release on June 15. If you’ve ever considered taking the leap from an 8-bit to a 32-bit processor without having to hassle through the setup of an ARM toolchain, now might be a great time to get started.

via [the Arduino Blog]

Arduino Controlled Air Conditioner

June 11, 2015 by Rich Bremer 31 Comments

Now that summer is coming, it’s time to break out the Air Conditioners! There are some old AC units out there that still work just fine, but nowadays we are used to everything being remotely controlled and automatic. [Phil] had an old window-mounted AC unit that still worked but was installed in a not-so-convenient place. To access the AC’s controls, one would have to climb over a large desk. This is a perfect opportunity to use the plethora of widely available hobby electronics to make an automatic AC controller retrofit.

First things first, there needs to be a way to turn the current control knob on the AC. [Phil] modeled up a 3D bracket to hold an RC car servo to the AC control panel. Attached to the servo horn is a slotted cylinder sized appropriately to fit the shape of the control knob. An Arduino measures the temperature of the room via a DS18B20 temperature sensor which then has the servo turn the control knob to the appropriate position, on or off. The Arduino sends temperature data back to a PC via MegunoLink Pro which graphs past data and also displays current temperature data. Using MegunoLink Pro, the min/max temperature points can also be set without uploading a new sketch to the Arduino.

From the temp vs time graph, it looks like the room temperature stays a consistent 23 +/- 1 °C. [Phil] did us summer-swelterers a favor and made all his design files available. This is a great idea but wonder if leaving the air conditioner unit switch in the ‘on’ position and turning the unit on/off via a relay connected to the 120vac line would work just as well.

Astoundingly Great $60 3D Printer Called Chimera Bests Your Printer

June 10, 2015 by Eric Evenchick 59 Comments

When most people think of 3D printing, they think of Fused Deposition Modelling (FDM) printers. These work by heating a material, squirting it out a nozzle that moves around, and letting it cool. By moving the nozzle around in the right patterns while extruding material out the end, you get a part. You’ve probably seen one of the many, many, many FDM printers out there.

Stereolithography printing (SLA) is a different technique which uses UV light to harden a liquid resin. The Chimera printer uses this technique, and aims to do it on the cheap by using recycled parts.

First up is the UV light source. DLP projectors kick out a good amount of UV, and accept standard video inputs. The Mitsubishi XD221u can be had for about $50 off eBay. Some modifications are needed to get the focus distance set correctly, but with that complete the X and Y axes are taken care of.

For the Z axis, the build platform needs to move. This was accomplished with a stepper motor salvaged from a disk drive. An Arduino drives the motor to ensure it moves at the right rate.

Creation Workshop was chosen as the software to control the Chimera. It generates the images for the projector, and controls the Z axis. The SLA process allows for high definition printing, and the results are rather impressive for such a cheap device. This is something we were just talking about yesterday; how to lower the cost of 3D printers. Obviously this is cheating a bit because it’s banking on the availability of cheap used parts. But look at it this way: it’s based on older technology produced at scale which should help a lot with the cost of sourcing this stuff new. What do you think?

On Your Phone While Driving An Electric Skateboard

June 9, 2015 by Rick Osgood 28 Comments

Skateboards are fun, but you have to do all that pesky kicking in order to get anywhere. That’s why [Nick] decided to build his own electric skateboard. Not only is the skateboard powered with an electric motor, but the whole thing can be controlled from a smart phone.

[Nick] started out with a long board deck that he had made years ago. After cleaning it up and re-finishing it, the board was ready for some wheels. [Nick] used a kit he found online that came with the trucks, wheels, and a belt. The trucks have a motor mount welded in place already. [Nick] used a Turnigy SK3 192KV electric motor to drive the wheels. He also used a Turnigy electronic speed controller to make sure he could vary the speed of the board while riding.

Next [Nick] needed some interface between a smart phone and the motor controller. He chose to use an Arduino Nano hooked up to a Bluetooth module. The Nano was able to directly drive the motor controller, and the Bluetooth module made it easy to sync up to a mobile phone. The Android app was written using MIT’s App Inventor software. It allows for basic control over the motor speed so you can cruise in style. Check out the video below for a slide show and some demonstration clips.

It’s a popular project, and eerily similar to the one we saw a couple months back.

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Galactic Dimension – A Supersized DIY Pinball Machine

June 5, 2015 by Anool Mahidharia 6 Comments

If you are from the 1960’s or 1970’s we know you would have enjoyed furiously punching the buttons of a pin ball machine back in the day. Installation artist [Niklas Roy] recently revisited this old classic game and built Galactic Dimension – a supersized pinball machine for Phæno – an amazing science center in the German city of Wolfsburg. The science centre was planning a big exhibition featuring thirty beautiful, classic pinball machines loaned from the Pacific Pinball Museum in Alameda, California.

The game machine was built on a steep ramp and has a gigantic play field measuring 3m x 6m (10’x20′). It features Sci-Fi game elements in the play field which blend perfectly with the futuristic building where it is housed. The game elements are built from repurposed everyday items like hair dryers and fans, giving visitors the motivation to build some of their own such contraptions.

The players operate the machine via a control desk, and a giant calculator is used to display the game score. The steep ramp had an incline of almost 30° which meant that he had to use a light ball to be able to propel it around the play field. The main user controls are the two flippers, and building giant ones was a big challenge. Solenoids or coils would not cut the ice, and he settled for pneumatic cylinders – easy to control, powerful, not too loud, and the museum already had a compressed air supply readily available. But it still took him three iterations before he could get it right. The plunger, which initially propels the ball, was built from PVC pipes and a hair dryer. Each play field element was built as a separate module to make assembly and maintenance easier. All featured a 220V AC supply, a sensor (either an IR distance sensor or a light barrier) to detect the ball, and an Arduino. Actuators were built from hair dryers and portable fans. Each of them have their own sound effects too – either a hacked toy or a speaker controlled by the Arduino. After everything was built, taken apart, transported, and reassembled at the site, the Galactic Dimension worked without a glitch, and without releasing any magic smoke. To top it off, Andreas Harre, who’s been the German pinball champion for several years in a row, also played the machine when he visited Phæno – and was totally excited about it!

So if you are in that part of Germany anytime until September, do drop in and try to ring up a big score. For photos of his build log, check out the photo album. There’s also a fairly big block diagram (German) and the Arduino sketches (.zip file), if you’d like to take a stab at building an even bigger pinball machine. Check the video to see the machine in action. And if the name [Niklas] sounds familiar, it is because he loves building installations such as the Forbidden Fruit Machine, the Ball Sucking Machine, and another Ball Sucking Machine.

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Googly Eyes Follow You Around The Room

June 4, 2015 by Bryan Cockfield 15 Comments

If you’re looking to build the next creepy Halloween decoration or simply thinking about trying out OpenCV for the first time, this next project will have you covered. [Glen] made a pair of giant googly eyes that follow you around the room using some servos and some very powerful software.

The project was documented in three parts. In Part 1, [Glen] models and builds the eyes themselves, including installing the servo motors that will eventually move them around. The second part involves an Arduino and power supply that will control the servos, and the third part goes over using OpenCV to track faces.

This part of the project is arguably the most interesting if you’re new to OpenCV; [Glen] uses this software package to recognize different faces. From there, the computer picks out the most prominent face and sends commands to the Arduino to move the eyes to the appropriate position. The project goes into great detail, from Arduino code to installing Ubuntu to running OpenCV for the first time!

We’ve featured some of [Glen]’s projects before, like his FPGA-driven LED wall, and it’s good to see he’s still making great things!

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