DIY Wire Bender Gets Wires All Bent Into Shape

It’s been a while since we’ve shown a DIY wire bending machine, and [How To Mechatronics] has come up with an elegant design with easy construction through the use of 3D-printed parts which handle most of the inherent complexity. This one also has a Z-axis so that you can produce 3D wire shapes. And as with all wire bending machines, it’s fun to watch it in action, which you can do in the video below along with seeing the step-by-step construction.

One nice feature is that he’s included a limit switch for automatically positioning the Z-axis when you first turn it on. It also uses a single 12 volt supply for all the motors, and the Arduino that acts as the brains. The 5 volts for the one servo motor is converted from 12 using an LM7805 voltage regulator. He’s also done a nice job packaging the Arduino, stepper motor driver boards, and the discrete components all onto a single custom surface mount PCB.

Wire straightener and feeder
Wire straightener and feeder

The bender isn’t without some issues though, such as that there’s no automatic method for giving it bending instructions. You can write code for the steps into an Arduino sketch, which is really just a lot of copy and paste, and he’s also provided a manual mode. In manual mode, you give it simple commands from a serial terminal. However, it would be only one step more to get those same commands from a file, or perhaps even convert from G-code or some other format.

Another issue is that the wire straightener puts too much tension on the wire, preventing the feeder from being able to pull the wire along. One solution is to feed it pre-straightened wire, not too much to ask for since it’s really the bending we’re after. But fixing this problem outright could be as simple as changing two parts. For the feeder, the wire is pulled between copper pipe and a flat steel bearing, and we can’t help wondering whether perhaps replacing them with a knurled cylinder and a grooved one would work as the people at [PENSA] did with their DIWire which we wrote about back in 2012. Sadly, the blog entries we linked to no longer work but a search shows that their instructable is still up if you want to check out their feeder parts.

As for the applications, we can think of sculpting, fractal antennas, tracks for marble machines, and really anything which could use a wireframe for its structure. Ideas anyone?

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Video Review: AND!XOR DEF CON 26 Badge

The AND!XOR team have somehow managed to outdo themselves once again this year. Their newest unofficial hardware badge for DEF CON 26 just arrived. It’s a delightful creation in hardware, software, and the interactive challenges built into both.

They call this the “Wild West of IoT”, a name that draws from the aesthetic as well as the badge-to-badge communications features. Built on the ESP32-WROVER module which brings both WiFi and Bluetooth to the party, the badges are designed to form a wireless botnet at the conference. Anyone with a badge can work to advance their level and take more and more control of the botnet as they do.

Check out the video overview and then join me below for a deeper dive into all this badge has to offer.

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Hands-On: New AND!XOR Unofficial DEF CON Badge

In just two weeks, we’ll be flooding into the casinos of Las Vegas for DEF CON. By far our favorite part is the unofficial hardware badges which make their way to the con each year. The AND!XOR team has put together an incredible offering this year with what I’m calling the “Bender on a Bender” badge. They sent us two of them, so let’s jump right in and see what this badge is all about.

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Hardware Tribes Growing Up Around Artisanal Electronics

Consumer electronics are design beasts that must serve many masters. There’s a price point for the product itself, a ceiling for the feature set (lest it not be ‘user friendly’), and to take the risk of actually manufacturing something there needs to be proof of the market. A lot of great things make it through this process, but some really unique and special gear goes completely around it.

So is the story of this AND!XOR hardware badge being built for DEF CON 25. This is not the official conference badge, but the latest in a growing trend of hardware/firmware engineers and hackers who design their own custom gear for the conference, trying to one-up not just the official badge, but the other hardware tribes doing the same. This unique hardware excitement is a big reason that Hackaday has developed electronic badges for our conferences.

The new badge is a mashup of Bender from Futurama and Raoul Duke from Fear and Loathing in Las Vegas, presents something of monstrosity to hang around your neck. That has certainly never stopped us from having one of these bouncing around our necks as we pound the cattle paths from talk to talk (and the DC23 vinyl record was way more unwieldy anyway).

Bender’s forehead display has now been upgraded from a diminutive OLED to a generous color LCD display. The 433 MHz which used the spring antenna on the previous badge has given way to a Bluetooth Low Energy. The BLE is built into the Rigado BMD-300 SOC that is now in conrol of the badge. We can’t wait to see the shenanigans unlocked with this new hardware — they’re already showing of crazy animations, retro gaming, and teasing a huge multiplayer game with all the badges. Finally, the “Secret Component” at the bottom of their components list delivers the je ne sais quoi to the whole project.

Fans of AND!XOR have already thrown their weight behind it. Unofficial badges have been unavailable to a wider group or only offered in flash-sales that pop up during the con. Last year the team was met with a huge mob throwing money at their supply of 175 badges. Now the AND!XOR team has grown to five people toiling away to make the design, the easter-egg laden firmware, and the manufacturing process better than the amazing work of last year. They just launched a crowd funding campaign on Tuesday and immediately blew past their goal about five times over.

We’re hoping to get our mitts on one of these ahead of DEF CON to give you an early look at what these hardware artists have accomplished. If you’re part of another hardware tribe building custom electronics for the love of it, we’d really like to hear from you. This goes for any conference — we know of at least one other in progress.

DIY Roll Bender Keeps it Simple and Sturdy

If you’ve ever tried to bend a metal pipe or bar over your knee, you’ll know that even lightweight stock requires quite a bit of force. And the force needs to be properly directed, lest the smooth bend you seek become a kink or a crease. When your hands and knees no longer fill the bill, try [MakeItExtreme]’s sturdy and simple roll bender.

As we watched the video below, we had a little déjà vu — hadn’t the [MakeItExtreme] crew built a roll bender for their shop before? Turns out they had, but in reviewing that video, we can see why they gave it a second shot. This build is a model of simplicity compared to the previous. With a frame fabricated from just a few pieces of steel I-beam, this version is far more approachable than its big brother and just about as capable. The three forming rollers ride in stout pillow blocks and can be repositioned for different bending radii. A 2-ton hydraulic bottle jack provides the force needed to direct the stock through the rollers, which are manually powered. In a nice touch, the incomplete tool was used to create the rim of the large-diameter handwheel for the drive roller.

The tools keep piling up at [MakeItExtreme]’s open air workshop — we even get a glimpse of their heavy-lift electromagnet that we recently featured. As always, we love the fit and finish on these builds, and watching the time-lapse videos is like a condensed class in metalworking.

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Animatronic Head Responds with Animated GIFs

[Abhishek] describes Peeqo as a “personal desktop robotic assistant” that looks like “the love child of an Amazon Echo and a Disney character.” We’re not sure about that last part — we’re pretty sure [Bender Bending Rodriquez] would fail a paternity suit on this one. Just look at that resemblance.

vkwnaidWhatever Peeqo’s parentage may be, it’s a pretty awesome build, and from the look of [Abhishek]’s design notes, he put a lot of thought into it, and a lot of work too. The build log reveals 3D-printed parts galore, custom-etched PC boards, and a hacked Raspberry Pi to both listen for voice commands and play responses in the form of animated GIFs on Peeqo’s ‘face’. The base has six modified RC servos to run the Gough-Stewart platform that lets Peeqo emote, and the head contains pretty much all the electronics. Beyond the hardware, a ton of programming went into giving Peeqo the ability to communicate through head gestures and GIFs that make sense for the required response.

Whether it’s bopping along to the tunes on your playlist or motivating you to lay off the social media with [Will Ferrell]’s flaming angry eyes, Peeqo looks like a ton of fun to build and use. Conveniently enough, [Abhishek] has shared all his files so you can build one too.

We haven’t seen anything like Peeqo before, but we have seen a lot of Amazon Echo hacks and even a few Stewart platform builds. But did we inadvertently feature a project starring Peeqo’s dad way back in 2009?

[Thanks to Aaron Cofield for the tip]

Hands-on the AND!XOR Unofficial DEF CON Badge

DEF CON 24 is still about two weeks away but we managed to get our hands on a hardware badge early. This is not the official hardware — there’s no way they’d let us leak that early. Although it may be unofficial in the sense that it won’t get you into the con, I’m declaring the AND!XOR badge to be officially awesome. I’ll walk you through it. There’s also a video below.

Over the past several years, building your own electronic badge has become an impromptu event. People who met at DEF CON and have been returning year after year spend the time in between coming up with great ideas and building as many badges as they can leading up to the event. This is how I met the trio who built this badge — AND!XORAndrew Riley, and Jorge Lacoste — last year they invited me up to their room where they were assembling the last of the Crypto Badges. Go check out my guide to 2015 Unofficial DEF CON badges for more on that story (and a video of the AM transmissions that badge was capable of).

The outline is this year’s badge is of course Bender from Futurama. Both eyes are RGB LEDs, with another half dozen located at different points around his head. The microcontroller, an STM32F103 ARM Cortex-M0 Cortex-M3, sits in a diamond pattern between his eyes. Above the eyes you’ll find 16 Mbit of flash, a 128×64 OLED screen, and a reset button. The user inputs are five switches and the badge is powered by three AA batteries found on the flip side.

bender's-nose-closeup

That alone makes an interesting piece of hardware, but the RFM69W module makes all of the badges interactive. The spring coming off the top of Bender’s dome is a coil antenna for the 433 MHz communications. I only have the one badge on hand so I couldn’t delve too deeply what interactive tricks a large pool of badges will perform, but the menu hints at a structure in place for some very fun and interesting applications.

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