Chemistry

137 Articles

Basically, Galvanizing Metal Without Acid

September 26, 2026 by 31 Comments

As useful as steel and iron are to the modern world, their tendency to rust is a major downside. There’s a spectrum of ways to prevent it, from quickly slapping on a coat of paint to alloying, chromizing, or physical vapor deposition. For a middle ground accessible to the home shop, galvanizing is a go-to method of rust prevention that deposits a layer of zinc onto the metal instead, but even this generally involves the use of strong acids. This method makes galvanizing accessible without any acids. (Spoiler alert: substitute strong bases.)

Although the acids are omitted, the solution is caustic, so similar safety measures are still advised. The first step in the process is to dissolve sodium hydroxide into a container of distilled water. Metallic zinc can then be dissolved in the solution, with a bit of sugar and liquid soap to improve the finished quality of the coating. An electric current is applied to the solution, using a graphite plate at the anode and the part to be electroplated as the cathode. After some time, the part will be uniformly coated in a layer of zinc, which can then be brightened in a solution of only-mildly-acidic citric acid if needed.

One of the benefits of using a strong base to galvanize a metal part, beyond the preference of avoiding strong acids, is that this process can be better at plating parts that are non-uniform in shape, so things with deep crevices or other odd shapes that might coat unevenly in acid. If there’s a preference for electroplating with acid, there are some ways of producing one’s own using various methods.

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Turning Energy Drinks Into Rocket Fuel

August 15, 2026 by 13 Comments

Sometimes claimed to give you wings, energy drinks can, at the very least, be used to make rockets fly. This is what [Nate Scovill] did in a recent video, where cans of the sugary stuff are processed to give a rocket its proverbial wings.

The basic concept is so-called rocket candy, which uses the fact that sugar is a pretty decent fuel type that — when combined with an oxidizer like potassium nitrate — can be turned into solid rocket fuel. Naturally it’d be easiest to start off with a pure source of sucrose or sorbitol for the sugar, but what if you only have access to cans of sugary soda?

Removing the moisture from the energy drink was the obvious first step, as water and rocket fuel aren’t a great mix. Adding and mixing potassium nitrate to the resulting thick syrup created the fuel-oxidizer mixture, also known as rocket fuel. This did take a detour involving removing the carbonation using a vacuum chamber, as CO2 and fire do not really like each other either.

We previously covered making your own rocket candy, though it’s far from the only rocket fuel that can be made at home using products bought at the local supermarket. Obviously, doing so comes with a whole heap of risks, not least of which is the notion that the difference between a rocket and a bomb is a pretty thin and fuzzy line that you do not want to accidentally cross.

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Art of 3D printer in the middle of printing a Hackaday Jolly Wrencher logo

Is Now The Time For Volumetric 3D Printing?

July 7, 2026 by 29 Comments

Of all innovations adopted by the maker community within the past couple of decades, one stands among the rest on top for anything regarding manufacturing. It goes without saying here at Hackaday how many projects have been reliant on using the technology to turn their ideas into reality. 3D printing has been a maker community invention and, in return, has expanded this hacky community into something that anyone with an imagination can get into. It also goes without saying that the layer-based tech imposes limits on what we can actually create: think overhangs and layer adhesion. However, there’s a possibility that a recent offshoot of this scrappy community has the power to eliminate some of these faults.

Volumetric additive manufacturing (VAM) is a young technology that has a similar start to many new tech toys, including the original SLA of the first 3D printers. That is expensive and completely stuck in the laboratory… Fortunately, that’s not where 3D printing as a whole stayed, as the RepRap project managed to bring the obscure technology to the hobbyists’ main stage. An entire group of people formed and spent countless hours until the useless pieces of poorly extruded plastic could form parts impossible to make with anything else. A cool quirk of history is that it likes to repeat: examples spur recreation, and this appears to be happening with the technology found within VAM printing.

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Microdistillery For Microchemistry

July 3, 2026 by 21 Comments

Much like radio operators being encouraged to use the least possible amount of power to make a contact, chemists have a similar rule encouraging using the least amount of materials in experiments. Not only is this rooted in economics, but in safety as well; if something goes wrong it’s generally good if there’s not excess amounts of reactants. With modern techniques, though, it’s possible to bring experimental chemistry down to incredibly small scales, and [Marb’s lab] found that they needed a custom built still for these new, diminutive experiments.

The first step is to build the heating component of the still. This is provided with a few custom aluminum parts for the base and a pair of heaters originally meant for 3D printers, with the assembled unit wrapped in insulation. The heater accomodates a 25 mL round-bottom flask. Temperature control of the heating mantle is provided by a controller mounted to a DIN rail which receives power from a 24V power supply, and an additional temperature probe is added to measure the temperature of the distillate. A test run with water shows the small still quickly and efficiently evaporating the water up to a condenser.

Although building a still doesn’t have to be technically difficult, building something this small that’s effective and safe is a bit more challenging than a backyard moonshining operation. Scaling chemical reactions down can often be a challenge but is possible with the right mindset and equipment. We’ve seen miniaturization of many things that we might not have expected including hydrogen production, aluminum smelting, and even the construction of a microscope.

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Solid-State Batteries Take To The Sky

June 17, 2026 by 13 Comments

There always seem to be a handful of revolutionary technologies perpetually out of reach: fusion energy, quantum computers, and full self-driving cars are always in this list, and it seems like there’s also some battery technology which will finally let us fully decouple from fossil fuels in there as well. Although lithium batteries have allowed some ground-based electric transportation, the energy density is still not enough to enable full electrification, especially for things like aircraft. Solid state batteries may be on the verge of changing some of this, though, and a team has recently put them to work in a test aircraft to help make some headway with this novel battery chemistry.

The main contributing factor of these batteries’ improved energy densities is the ability to use a solid lithium anode, which has much higher energy density than the graphite-based anodes in modern liquid electrolyte batteries. Solid state batteries also have improved safety, since the solid electrolyte is generally not flammable and the battery itself is less prone to thermal runaway. The tests in this aircraft, a modified motorized glider, bear this out as well. With a standard lithium ion pack the team was able to harness 250 Wh/kg and with their new solid state battery they managed 410 Wh/kg, which let them fly the craft up to 24,000 feet (7,315 m) with the help of some wing-mounted solar panels.

Of course, a motorized glider is a long way away from battery-powered commercial flights, but tests like this are an important step on the way to de-carbonizing one of the more impactful industries on the planet, as well as hopefully making it less expensive to operate aircraft in the way EVs are generally much cheaper to operate than their internal combustion equivalents. But the limiting factor to adopting solid state batteries isn’t going to be implementation but rather the discovery of a cost effective way to manufacture them at scale. It’s the same reason we haven’t seen mass adoption of things like algae-based biodiesel or economic carbon capture yet.

Introducing Boron Buckyballs

June 10, 2026 by 17 Comments

A buckminsterfullerene, also known as a buckyball, is typically a fullerene consisting of sixty carbon atoms (C60) arranged in a way that resembles a football-like sphere. Extending this arrangement to other types of atoms has until now however proven as elusive as finding non-carbon-based lifeforms. In a paper by [Hyun Wook Choi] et al. and published in Chemical Science the discovery of boron buckyballs is detailed. There is also a soft-paywalled article in the Chemical & Engineering News magazine for a higher-level perspective.

The discovered boron-based buckyball ups the number of atoms to eighty, forming B80 (boron fullerite) with a slightly larger diameter than C60 at 0.85 nm versus 0.71 nm. Perhaps more interesting are the claims by the authors that boron fullerite may have more practical applications than its carbon-based cousin, mostly due to it being predicted to be a semiconductor with an 0.8 eV energy gap and better electron acceptance that provides interesting doping prospects.

Producing these boron structures used laser vaporization with a helium carrier gas that was seeded with argon to increase cooling efficiency. Inside this boron cluster the reported structures were then discovered and characterized as described in the paper.

Obviously, going from a fascinating laboratory discovery to bulk production won’t be easy, and the predicted properties of boron fullerite may turn out to be incomplete or have a dark side that we aren’t aware of. Regardless, they’re bound to be more useful at least than the carbon version that’s remained mostly a curiosity despite many years of research.

Be Your Own Oil Company With Desktop Fischer-Tropsch Process

May 29, 2026 by 27 Comments

Plastics, oil, petrol– the modern world is entirely dependent on hydrocarbons. The good sources are slowly running low and supply is increasingly complicated by geopolitical factors we really don’t want to get into, but hey! It’s just hydrogen and carbon, right like it says in the name. How hard could it be to roll your own at home. Well, if you’ve got a lab like [Marb]’s Lab on YouTube, it might just be doable, as he demonstrates in his latest video.

The Fischer-Tropsch reaction was discovered back in 1925 in Germany by a couple of gents named Fischer and Tropsch. In the unpleasantness that followed later, Germany made good use of their process on an industrial scale, since they had ample coal and no oil on hand. Coal-rich South Africa has also made us of it, particularly during the Apartheid-era trade restrictions. Every so often the idea of industrializing the process comes up in the USA, but there’s still enough oil there it doesn’t make sense economically.

Those nations all have something in common: they’re all coal-rich countries, and that makes sense because coal is easily converted to carbon monoxide and hydrogen– a combo known as syngas– and it just so happens that those are the feedstock for this reaction. The actual chemistry going on inside is quite complex, but conceptually it is pretty simple: hydrogen and carbon monoxide mix over a hot metal catalyst, and combine to form various hydrocarbons.

In [Marb]’s glassware-based demonstration, the catalyst is Cobalt (III) Oxide on silica gel– a lovely, cancer-causing substance that must be prepared for each use, as it lasts but 24 hours before further oxidization ruins it. That’s in spite of purging the system with argon– a necessary step if one does not wish to explode. The yield isn’t amazing, and [Marb] isn’t sure exactly what mix of hydrocarbons he has created– although they smell like gasoline and burn like the dickens, so mission accomplished.

This might seem like the furthest thing from green, but if you use solar power to run the process and something like woodgas– which is syngas by any other name– as a feed-stock, then you’ve got a carbon neutral energy storage medium.

Thanks to [Markus Bindhammer] for the tip!

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