Form 3 SLA Printer Teardown, Bunnie Style

[Bunnie Huang] has shared with all of us his utterly detailed teardown on the Form 3 SLA printer from Formlabs (on the left in the image above) and in it he says one of the first things he noticed when he opened it to look inside was a big empty space where he expected to see mirrors and optics. [Bunnie] had avoided any spoilers about the printer design and how it worked, so he was definitely intrigued.

The view inside the Form 3.

Not only does the teardown reveal the kind of thoughtful design and construction that [Bunnie] has come to expect of Formlabs, but it reveals that the Form 3 has gone in an entirely new direction with how it works. Instead of a pair of galvanometers steering a laser beam across a build surface (as seen in the Form 1 and Form 2 printers) the new machine is now built around what Formlabs calls an LPU, or Light Processing Unit, which works in conjunction with a new build tank and flexible build surface. In short, the laser and optics are now housed in a skinny, enviromentally-sealed unit that slides left and right within the printer. A single galvo within steers the laser vertically, as the LPU itself moves horizontally. Payoffs from this method include things such as better laser resolution, the fact that the entire optical system is no longer required to sit directly underneath a vat of liquid resin, and that build sizes can be bigger. In addition, any peeling forces that a model is subjected to are lower thanks to the way the LPU works.

Details about exactly how the Form 3 works are available on Formlabs’ site and you can also see it in action from a practical perspective on Adam Savage’s Tested (video link), but the real joy here is the deeply interesting look at the components and assembly through the eyes of someone with [Bunnie]’s engineering experience. He offers insights from the perspective of function, supply, manufacture, and even points out a bit of NASA humor to be found inside the guts of the LPU.

[Bunnie] knows his hardware and he’s certainly no stranger to Formlabs’ work. His earlier Form 2 teardown was equally detailed as was his Form 1 teardown before that. His takeaway is that the Form 3 and how it works represents an evolutionary change from the earlier designs, one he admits he certainly didn’t see coming.

Hackaday Podcast 048: Truly Trustworthy Hardware, Glowing Uranium Marbles, Bitstreaming The USB, Chaos Of Congress

Hackaday editors Elliot WIlliams and Mike Szczys kick off the first podcast of the new year. Elliot just got home from Chaos Communications Congress (36c3) with a ton of great stories, and he showed off his electric cargo carrier build while he was there. We recount some of the most interesting hacks of the past few weeks, such as 3D-printed molds for making your own paper-pulp objects, a rudimentary digital camera sensor built by hand, a tattoo-removal laser turned welder, and desktop-artillery that’s delivered in greeting-card format.

Take a look at the links below if you want to follow along, and as always tell us what you think about this episode in the comments!

Direct download (69 MB)

Places to follow Hackaday podcasts:

Continue reading “Hackaday Podcast 048: Truly Trustworthy Hardware, Glowing Uranium Marbles, Bitstreaming The USB, Chaos Of Congress”

Bunnie Huang Talks Manufacturing And Component Choices During Hackaday Prize Mentoring Session

Andrew “Bunnie” Huang’s mentor session for the Hackaday Prize shows off the kind of experience and knowledge hard to come by unless you have been through the hardware development gauntlet countless times. These master-classes match up experts in product development with Prize entrants working to turn their projects into products. We’ve been recording them so that all may benefit from the advice and guidance shared in each session.

The appealing little FunKey pocket gaming platform.
The appealing little FunKey pocket gaming platform.

Bunnie is someone who is already familiar to most Hackaday readers. His notoriety in our community began nearly two decades ago with his work reverse engineering the original Microsoft X-box, and he quickly went on to design (and hack) the Chumby Internet appliance, he created the Novena open-source laptop, and through his writing and teaching, he provides insight into sourcing electronic manufacture in Shenzhen. He’s the mentor you want to have in your corner for a Hackaday Prize entry, and that’s just what a lucky group had in the video we’ve placed below the break.

While this session with Bunnie is in the bag it’s worth reminding you all that we are still running mentor sessions for Hackaday Prize entrants, so sign up your entry for a chance to get some great feedback about your project.

The first team to meet with Bunnie are FunKey, whose keychain Nintendo-like handheld gaming platform was inspired by a Sprite_tm project featuring a converted novelty toy. The FunKey team have produced a really well-thought-out design that is ready to be a product, but like so many of us who have reached that point they face the impossible hurdle of turning it into a product. Their session focuses on advice for finding a manufacturing partner and scaling up to production.

A prototype HotorNot Coffee Stirrer, showing their problem of having to maintain food-safe components.
A prototype HotorNot Coffee Stirrer, showing their problem of having to maintain food-safe components.

HotorNot Coffee Stirrer is trying to overcome a problem unique to their food-related project. A hot drink sensor that has to go in the drink itself needs to be food safe, as well as easy enough to clean between uses. A variety of components are discussed including a thermopile on a chip that has the advantage of not requiring contact with the liquid, but sometimes the simplest ideas can be the most effective as Bunnie reminds us that a cheap medical thermometer teardown can tell us a lot about appropriate parts for this application.

The idea behing PhalangePad is an attractive one, but making those sensors reliable is no trivial eercise.
The idea behing PhalangePad is an attractive one, but making those sensors reliable is no trivial eercise.

It’s another component choice problem that vexes PhalangePad, an input device that relies on the user tapping the inside of their fingers with their thumb. It’s a great idea, but how should these “keypresses” be detected? Would you use a capacitive or magnetic sensor, a force sensitive resistors, or maybe even machine vision? Here Bunnie’s encyclopaedic knowledge of component supply comes to the fore, and the result is a fascinating insight into the available technologies.

We all amass a huge repository of knowledge as we pass through life, some of the most valuable of which is difficult to pass on in a structured form and instead comes out as incidental insights. An engineer with exceptional experience such as Bunnie can write the book on manufacturing electronics in China but still those mere pages can only scratch the surface of what he knows about the subject. There lies the value of these mentor sessions, because among them the gems of knowledge slip out almost accidentally, and if you’re not watching, you’ll miss them.

This is the second in our series of Hackaday Prize mentoring sessions this year, but we have more already in the can and further sessions to record. We’re constantly looking for more participants though, so make sure if you haven’t already that you put your entry in for Hackaday Prize and check out the list of mentors who are here to share their knowledge and experience. Continue reading “Bunnie Huang Talks Manufacturing And Component Choices During Hackaday Prize Mentoring Session”

Your Masterclass In Product Design: Hackaday Prize Mentor Sessions

New to this year’s Hackaday Prize is a set of live mentor sessions and you’re invited! Being at the center of a successful product design project means having an intuitive sense in many, many areas; from industrial design and product packaging, to manufacturing and marketing. This is your chance to learn from those experts who have already been there and want to make your experience better and easier.

We want you to get involved by entering your own project into the Hackaday Prize; now is the time to tell us you’re ready to demo your project with a mentor. Hackaday Prize Mentor Sessions are happening every two weeks throughout the summer. In these video chats we’re inviting some promising Hackaday Prize entries to start off with a “demo day” type of presentation, followed by an interactive session with the mentor hosting each event.

It’s also important that this incredible resource be available to all, so these videos will be published once the mentor session wraps up. This is a master class format where the advice and shared experience have a beneficial effect far beyond the groups sharing their projects.

The 2019 Hackaday Prize focuses on product development. Show your path from an idea to a product design ready for manufacturing and you’ll be on target to share in more than $200,000 in cash prizes!

Meet Some of Our Mentors:

Below you will find just a taste of the mentor sessions in the works. These are the first three mentor session videos that will be published, but make sure you browse the full set of incredible mentors and get excited for what is to come!

Bunnie Huang

Co-founder, Chibitronics


Bunnie is best known for his work hacking the Microsoft Xbox, as well as
his efforts in designing and manufacturing open source hardware. His past projects include the chumby (app-playing alarm clock), Chibitronics (peel-and-stick electronics for crafting), and the Novena (DIY laptop). He currently lives in Singapore where he runs a private product design studio, Kosagi, and actively mentors several startups and students of the MIT Media Lab.

Mattias Gunneras & Andrew Zolty

Co-founders, BREAKFAST NY


Zolty and Mattias founded BREAKFAST in 2009. This studio of multidisciplinary artists and engineers conceives, designs, and fabricates high-tech contemporary art installations and sculptures. BREAKFAST has over 15 large-scale pieces that can be found in various museums, arenas, and lobby spaces throughout the world.

Giovanni Salinas

Product Development Engineer, DesignLab


Giovanni is the Product Development Engineer at Supplyframe DesignLab. He has designed and developed hundreds of products, including consumer electronics, kitchenware, and urban furniture for the North American, European, Chinese and Latin American markets. Through his experience he has honed his expertise in rapid prototyping and DFM in plastics, wood, and metals.

We Want You To Demo Your Product!

Mentor sessions will continue throughout the summer with these and other mentors! Sign up to demo your 2019 Hackaday Prize entry!

A Farmer’s Guide To Technology

One of the hardest aspects of choosing a career isn’t getting started, it’s keeping up. Whether you’re an engineer, doctor, or even landscaper, there are always new developments to keep up with if you want to stay competitive. This is especially true of farming, where farmers have to keep up with an incredible amount of “best practices” in order to continue being profitable. Keeping up with soil nutrient requirements, changing weather and climate patterns, pests and other diseases, and even equipment maintenance can be a huge hassle.

A new project at Hackerfarm led by [Akiba] is hoping to take at least one of those items off of farmers’ busy schedules, though. Their goal is to help farmers better understand the changing technological landscape and make use of technology without having to wade through all the details of every single microcontroller option that’s available, for example. Hackerfarm is actually a small farm themselves, so they have first-hand knowledge when it comes to tending a plot of land, and [Bunnie Huang] recently did a residency at the farm as well.

The project strives to be a community for helping farmers make the most out of their land, so if you run a small farm or even have a passing interest in gardening, there may be some useful tools available for you. If you have a big enough farm, you might even want to try out an advanced project like an autonomous tractor.

Tearing Down The Boss Phone

Poke around enough on AliExpress, Alibaba, and especially Taobao—the Chinese facing site that’s increasingly being used by Westerners to find hard to source parts—and you’ll come across some interesting things. The Long-CZ J8 is one of those, it’s 2.67 inch long and weighs just 0.63 ounces, and it’s built in the form factor of a Bluetooth headset.

A couple of months ago Cory Doctorow highlighted this tiny phone, he’d picked up on it because of the marketing. The lozenge-shaped phone was being explicitly marketed that it could “beat the boss”. The boss in question here being the B.O.S.S chair—a scanning technology that has been widely deployed across prisons in the U.K. in an attempt to put a halt to smuggling of mobile phones to inmates.

The Long-CZ J8 is just 2.67 inch (6.8cm) long.

I wasn’t particularly interested in whether it could make it through a body scanner, or the built-in voice changer which was another clue as to the target market for the phone. However just the size of the thing was intriguing enough that I thought I’d pick one up and take a look inside. So I ordered one from Amazon.

Continue reading “Tearing Down The Boss Phone”

Bunnie And Snowden Explore IPhone’s Hackability

[Bunnie Huang] and [Edward Snowden] have teamed up to publish a paper exploring the possibility of introspection on the iPhone.

A rendering of the proposed introspection device attached to an iPhone6
A rendering of the proposed introspection device attached to an iPhone6

The idea is that phones are increasingly complex and potentially vulnerable to all kinds of digital surveillance. Even airplane mode is insufficient for knowing that your phone isn’t somehow transmitting information. The paper looks at the various radios on the iPhone, going so far as opening up the device and reading signals at each of the chips for cell, WiFi, Bluetooth, GPS, and NFC to determine whether the chip itself is doing anything, regardless of what the screen says. This introspection can then be used to be confident that the phone is not communicating when it shouldn’t be.

The paper goes on to propose a device that they will prototype in the coming year which uses an FPC that goes into the phone through the SIM card port. It would contain a battery, display, buttons, multiple SIM cards, and an FPGA to monitor the various buses and chips and report on activity.

Significant hacking of an iPhone will still be required, but the idea is to increase transparency and be certain that your device is only doing what you want it to.