Ask Hackaday: How Do You Make Front Panels?

June 20, 2024 by Al Williams 49 Comments

We’ll admit it. The closer a project is to completion, the less enthusiasm we have for it. Once the main design is clearly going to work on a breadboard, we’re ready to move on to the next one. We don’t mind the PCB layout, especially with modern tools. However, once the board is done, you have to do the case. Paradoxically, this was easier in the old days because you just picked some stock box, drilled some holes, and while it looked terrible, it was relatively easy.

Today, the bar is much higher. You’ll probably 3D print or laser cut an enclosure. If it looks no better than what you did in the 1970s, you won’t win many admirers. We routinely cover projects that could easily pass for commercial products. So how do you do it?

The Parts

The enclosure may even be the easy part. There are plenty of scripts and generators that will make you a nice box that meets your specifications. You can probably even get the holes made as you build. Back in the day, it was a challenge to cut odd-shaped holes for things like serial port connectors. Now, no problem. The printer or laser will just make a hole with any shape you like. You may even want to try a new angle on 3D printing.

Mounting the PCB isn’t that hard, either. With 3D printing, you can create standoffs, but even if you laser cut, you can easily use conventional standoffs. In a pinch, we’ve used long bolts with nuts.

The real problem, it seems to us, is the front panel. Only Star Trek can get away with front panels containing a bunch of knobs and dials with no markings. And although we call them “front” panels, sometimes you need markings on the back or even the sides, too. Continue reading “Ask Hackaday: How Do You Make Front Panels?” →

Ask Hackaday: Why Are Self-Checkouts Failing?

January 16, 2024 by Al Williams 260 Comments

Most people who read Hackaday have positive feelings about automation. (Notice we said most.) How many times have you been behind someone in a grocery store line waiting for them to find a coupon, or a cashier who can’t make change without reading the screen and thought: “There has to be a better way.” The last few years have seen that better way, but now, companies are deciding the grass isn’t greener after all. The BBC reports that self-checkouts have been a “spectacular failure.” That led us to wonder why that should be true.

As a concept, everyone loves it. Stores can hire fewer cashiers. Customers, generally, like having every line open and having a speedy exit from the store. The problem is, it hasn’t really panned out that way. Self-checkout stations frequently need maintenance, often because it can’t figure out that you put something in the bag. Even when they work flawlessly, a customer might have an issue or not understand what to do. Maybe you’ve scanned something twice and need one of them backed off. Then, there are the age-restricted products that require verification. So now you have to hire a crew of not-cashiers to work at the automated not-register. Sure, you can have one person cover many registers, but when one machine is out of change, another won’t print a receipt, and two people are waiting for you to verify their beer purchase, you are back to waiting. Next thing you know, there’s a line.

Continue reading “Ask Hackaday: Why Are Self-Checkouts Failing?” →

Ask Hackaday: Why Retrocomputing?

August 16, 2023 by Al Williams 81 Comments

I recently dropped in on one of the Vintage Computer Festival events, and it made me think about why people — including myself — are fascinated with old computer technology. In my case, I lived through a lot of it, and many of the people milling around at VCF did too, so it could just be nostalgia. But there were also young people there.

Out of curiosity, I asked people about the appeal of the old computers on display there. Overwhelmingly, the answer was: you can understand the whole system readily. Imagine how long it would take you to learn all the hardware and software details of your current desktop computer CPU. Then add your GPU, the mass storage controllers, and your network interface. I don’t mean knowing the part numbers, specs, and other trivialities. I mean being able to program, repair, and even enhance it.

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Ask Hackaday: Split Rail Op Amp Power Supply

April 20, 2023 by Al Williams 83 Comments

Water cooler talk at the office usually centers around movies, sports, or life events. Not at Hackaday. We have the oddest conversations and, this week, we are asking for your help. It is no secret that we have a special badge each year for Supercon. Have you ever wondered where those badges come from? Sometimes we do too. We can’t tell you what the badge is going to be for Supercon 2023, but here’s a chance for you to contribute to its design.

What I can tell you is that at least part of the badge is analog. Part, too, is digital. So we were discussing a seemingly simple question: How do we best generate a bipolar power source for the op amps on a badge? Like all design requests, this one is unreasonable. We want:

Ideally, we’d like a circuit to give us +/- 9 V to +/- 12 V at moderately low current, say in the tens of milliamps. Actual values TBD.
Low noise: analog circuitry, remember?
Lightweight: it is going on a badge
Battery operated: the badge thing again
Cheap: we only have a couple bucks in the budget for power
Available in quantity: we’ll need ~600 of these

Continue reading “Ask Hackaday: Split Rail Op Amp Power Supply” →

Ask Hackaday: Stripping Wires With Lasers

September 8, 2022 by Al Williams 22 Comments

Most of us strip the insulation off wires using some form of metal blade or blades. You can get many tools that do that, but you can also get by with skillfully using a pair of cutters, a razor blade or — in a pinch — a steak knife. However, modern assembly lines have another option: laser stripping. Now that many people have reasonable laser cutters, we wonder if anyone is using laser strippers either from the surplus market or of the do-it-yourself variety?

We are always surprised that thermal strippers are so uncommon since they are decidedly low-tech. Two hot blades and a spring make up the heart of them. Sure, they are usually expensive new, but you can usually pick them up used for a song. The technology for lasers doesn’t seem very difficult, although using the blue lasers most people use in cutters may not be optimal for the purpose. This commercial product, for example, uses infrared, but if you have a CO₂ laser, that might be a possibility.

The technique has found use in large-scale production for a while. Of course, if you don’t care about potential mechanical damage, you can get automated stripping equipment with a big motor for a few hundred bucks.

We did find an old video about using a CO₂ laser to strip ribbon cable, but nothing lately. Of course, zapping insulation creates fumes, but so does lasering everything, so we don’t think that’s what’s stopping people from this approach.

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Ask Hackaday: Are Extruders The Only Feasible Tools For Toolchanging?

December 13, 2021 by Donald Papp 34 Comments

Toolchanging in 3D printers is no longer something from the bleeding edge; it’s going mainstream. E3D has a high-quality kit for a toolchanger and motion system, our own Joshua Vasquez has shared details about the open-source toolchanging Jubilee design, and just recently Prusa3D formally announced the Prusa XL, which promises toolchanging with up to five different extruders.

It’s safe to say toolchanging on 3D printers has stepped to the front, but what comes next? What kind of tools other than extruders make sense on a 3D printer?

First, let’s explain what makes separate extruders such fantastic tools. Being able to change extruders on-demand during a print enables things like true multi-material printing. Printing in more than one color or material will no longer be done by pushing different filaments through a single nozzle, which limits a print to materials that extrude under similar conditions and temperatures. Toolchanging means truly being able to print in multiple materials, even if they have different requirements, because each material has its own extruder. That’s a clear benefit, but what about tools other than extruders?

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Ask Hackaday: Why Don’t Automakers Make Their Own EV Batteries?

December 1, 2021 by Lewin Day 88 Comments

Sales of electric vehicles continue to climb, topping three million cars worldwide last year. All these electric cars need batteries, of course, which means demand for rechargeable cells is through the roof.

All those cells have to come from somewhere, of course, and many are surprised to learn that automakers don’t manufacture EV batteries themselves. Instead, they’re typically sourced from outside suppliers. Today, you get to Ask Hackaday: why aren’t EV batteries manufactured by the automakers themselves? Continue reading “Ask Hackaday: Why Don’t Automakers Make Their Own EV Batteries?” →