Hacking Digital Calipers For Automated Measurements And Sorta-Micron Accuracy

March 6, 2025 by Dan Maloney 14 Comments

We’ll take a guess that most readers have a set of digital calipers somewhere close to hand right now. The cheapest ones tend to be a little unsatisfying in the hand, a bit crusty and crunchy to use. But as [Matthias Wandel] shows us, these budget tools are quite hackable and a lot more precise than they appear to be.

[Matthias] is perhaps best known around these parts for making machine tools using mainly wood. It’s an unconventional material for things like the CNC router he loves to hate, but he makes it work through a combination of clever engineering and a willingness to work within the limits of the machine. To assess those limits, he connected some cheap digital calipers to a Raspberry Pi by hacking the serial interface that seems to be built into all of these tools. His particular calipers output a pair of 24-bit words over a synchronous serial connection a couple of times per second, but at a level too low to be read by the Pi. He solved this with a clever resistor ladder to shift the signals to straddle the 1.8 volt transition on the Pi, and after solving some noise problems with a few strategically placed capacitors and some software debouncing, he was gathering data on his Pi.

Although his setup was fine for the measurements he needed to make, [Matthias] couldn’t help falling down the rabbit hole of trying to milk better resolution from the calipers. On paper, the 24-bit output should provide micron-ish resolution, but sadly, the readings seem to fluctuate rapidly between two levels, making it difficult to obtain an average quickly enough to be useful. Still, it’s a good exercise, and overall, these hacks should prove handy for anyone who wants to dip a toe into automated metrology on a budget.

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DIY Digital Caliper Measures Up

November 8, 2024 by Al Williams 15 Comments

You might wonder why [Kevin] wanted to build digital calipers when you can buy them for very little these days. But, then again, you are reading Hackaday, so we probably don’t need to explain it.

The motivation, in this case, was to learn to build the same mechanism the commercial ones use for use in precise positioning systems. We were especially happy to see that [Kevin’s] exploration took him to a Hackaday.io project which led to collaboration between him and [Mitko].

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Are You Using Your Calipers Wrong?

August 20, 2024 by Al Williams 50 Comments

It used to be that calipers were not a common item to have in an electronics lab. However, smaller parts, the widespread use of 3D printers and machining tools, and — frankly — cheap imported calipers have made them as commonplace as an ordinary ruler in most shops. But are you using yours correctly? [James Gatlin] wasn’t and he wants to show you what he learned about using them correctly.

The video that you can see below covers digital and vernier calipers. You might think digital calipers are more accurate, in practice, they are surprisingly accurate, although the digital units are easier to read.

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Solar Panel Keeps Cheap Digital Calipers Powered Up

April 20, 2024 by Dan Maloney 40 Comments

There’s no doubt that cheap digital calipers are useful, especially when designing 3D-printed parts. Unfortunately, cheap digital calipers are also cheap, and tend to burn through batteries quickly. Sure, you can remove the battery when you’re done using them, but that’s for suckers — winners turn to solar power to keep their calipers always at the ready.

[Johan]’s solar upgrade begins with, unsurprisingly, a solar cell, one that just fits on the back of his digital calipers. Like most of these cheap calipers, this one is powered by a single 1.5 V LR44 button cell, while the polycrystalline solar cell is rated for 5 V, so [Johan] used a red LED as a crude voltage regulator. He also added a stack of fourteen 100 μF SMD capacitors soldered together in parallel. The 1206 devices form a 1,400 μF block that’s smaller than the original button cell so that everything fits in the vacated battery compartment. It’s pretty slick.

Given their agreeable price point, digital calipers are a tempting target for hacking. We’ve seen a ton of them, from accessibility add-ons to WiFi connectivity and even repurposing them for use as DROs. Ever wonder how these things work? We’ve looked at that, too.

Hackaday Links: April 9, 2023

April 9, 2023 by Dan Maloney 17 Comments

When it comes to cryptocurrency security, what’s the best way to secure the private key? Obviously, the correct answer is to write it on a sticky note and put it on the bezel of your monitor; nobody’ll ever think of looking there. But, if you’re slightly more paranoid, and you have access to a Falcon 9, you might just choose to send it to the Moon. That’s what is supposed to happen in a few months’ time, as private firm Lunar Outpost’s MAPP, or Mobile Autonomous Prospecting Platform, heads to the Moon. The goal is to etch the private key of a wallet, cheekily named “Nakamoto_1,” on the rover and fund it with 62 Bitcoins, worth about $1.5 million now. The wallet will be funded by an NFT sale of space-themed electronic art, because apparently the project didn’t have enough Web3.0 buzzwords yet. So whoever visits the lunar rover first gets to claim the contents of the wallet, whatever they happen to be worth at the time. Of course, it doesn’t have to be a human who visits.

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DIY Comparatron Helps Trace Tiny, Complex Objects

December 11, 2022 by Donald Papp 21 Comments

Hackers frequently find themselves reverse-engineering or interfacing to existing hardware and devices, and when that interface needs to be a physical one, it really pays to be able to take accurate measurements.

This is easy to do when an object is big enough to fit inside calipers, or at least straight enough to be laid against a ruler. But what does one do when things are complex shapes, or especially small? That’s where [Cameron]’s DIY digital optical comparator comes in, and unlike commercial units it’s entirely within the reach (and budget) of a clever hacker.

The Comparatron is based off a CNC pen plotter, but instead of a pen, it has a USB microscope attached with the help of a 3D-printed fixture. Serving as a background is an LED-illuminated panel, the kind useful for tracing. The physical build instructions are here, but the image should give most mechanically-minded folks a pretty clear idea of how it fits together.

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Precision DIY Calipers? That’s A Moiré!

March 7, 2018 by Lara Grant 23 Comments

Moiré patterns are a thing of art, physics, and now tool design! [Julldozer] from Mojoptix creatively uses a moiré pattern to achieve a 0.05 mm precision goal for his custom designed 3D printed calipers. His calipers are designed to validate a 3D print against the original 3D model. When choosing which calipers are best for a job, he points out two critical features to measure them up against, accuracy and precision which he explains the definition of in his informative video. The accuracy and precision values he sets as constraints for his own design are 0.5 mm and 0.05 mm respectively.

By experimenting with different parameters of a moiré pattern: the scale of one pattern in relation to the other, the distance of the black lines on both images, and the thickness of black and white lines. [Julldozer] discovers that the latter is the best way to amplify and translate a small linear movement to a standout visual for measurement. Using a Python script which he makes available, he generates images for the moiré pattern by increasing line thickness ratios 50:50 to 95:5, black to white creating triangular moiré fringes that point to 1/100th of a millimeter. The centimeter and millimeter measurements are indicated by a traditional ruler layout.

Looking for more tool hacks and builds? Check out how to prolong the battery life of a pair of digital calipers and how to build a tiny hot wire foam cutter.

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