Can Metal Plated 3D Prints Survive 400,000 Volts?

August 25, 2021 by Dave Rowntree 12 Comments

It appears they can. [Ian Charnas] wanted his very own Thor Hammer. He wasn’t happy to settle on the usual cosplay methods of spray painting over foam and similar flimsy materials. He presents a method for nickel plating onto a 3D printed model, using conductive nickel paint to prepare the plastic surface for plating. In order to reduce the use of hazardous chemistry, he simplifies things to use materials more likely to be found in the kitchen.

As the video after the break shows, [Ian] went through quite a lot of experimentation in order to get to a process that would be acceptable to him. As he says, “after all, if something is worth doing, it’s worth over-doing” which is definitely a good ethos to follow. Its fairly hard to plate metals and get a good finish, and 3D printed objects are by their nature, not terribly smooth. But, the effort was well rewarded, and the results look pretty good to us.

But what about the 400 kV I hear you ask? Well, it wouldn’t be Thor’s hammer, without an ungodly amount of lightning flying around, and since [Ian] is part of a tesla coil orchestra group, which well, it just kinda fell into place. After donning protective chainmail to cover his skin, he walks straight into the firing line of a large pair of musical tesla coils and survives for another day. Kind of makes his earlier escapade with jet-powered roller skates look mundane by comparison.

Continue reading “Can Metal Plated 3D Prints Survive 400,000 Volts?” →

An Homage To Daft Punk In Fan-Made Helmets Through The Years.

March 2, 2021 by Jenny List 32 Comments

It’s with sadness that we note the end to an end. The French dance music duo Daft Punk have split up, announced in a video that’s has already clocked 22 million views.The band have inspired hardware geeks across the world not just with their music but the way they present themselves. A perennial project has been to replicate in some way their iconic robot helmets.

Ben Heck's 2009 take on the helmet — Harrison Krix’s 2009 take on Guy-Manuel de Homem-Christo’s helmet.

The artists themselves have been reticent about the exact technology that powers their headgear, but while this is a source of endless mystery and speculation to the music press it’s safe to assume from our perspective that their designers have the same parts at their disposal as we have. Microcontrollers, EL wire, and LEDs are universal, so the challenge lies in artistic expression with the helmet design rather than in making the effects themselves. We’ve reached into the archives for a bit of Daft Punk helmet nostalgia, so stick on Harder Better Faster and lets take a look at them, er, one more time.

Continue reading “An Homage To Daft Punk In Fan-Made Helmets Through The Years.” →

Watch This Scaly Gauntlet’s Hypnotizing, Rippling Waves

December 22, 2020 by Donald Papp No comments

[Will Cogley]’s mechanized gauntlet concept sure has a hypnotizing look to it, and it uses only a single motor. Underneath the scales is a rod with several cams, each of which moves a lever up and down in a rippling wave as it rotates. Add a painted scale to each, and the result is mesmerizing. This is only a proof of concept prototype, and [Will] learned quite a few lessons when making it, but the end result is a real winner of a visual effect.

The gauntlet uses one motor, 3D printed hardware, and a mechanical linkage between the wrist and the rest of the forearm. Each of the scales is magnetically attached to the lever underneath, which provides some forgiveness for when one inevitably bumps into something. You can see the gauntlet without the scales in the video, embedded below the break, which should make clear how the prototype works.

The scales were created with the help of a Mayku desktop vacuum former by making lightweight copies of 3D printed scales. Interestingly, 3D printing each scale with full supports made for a useful mold; there was no need to remove supports from underneath the prints, because they are actually a benefit to the vacuum forming process. When vacuum forming, the presence of overhangs can lead to plastic wrapped around the master, trapping it, but the presence of the supports helps prevent this. 3D prints don’t hold up very well to the heat involved in vacuum forming, but they do well enough for a short run like this. Watch it in action and listen to [Will] explain the design in the video, embedded below.

Continue reading “Watch This Scaly Gauntlet’s Hypnotizing, Rippling Waves” →

Remoticon Video: How To 3D Print Onto Fabric With Billie Ruben

December 18, 2020 by Kerry Scharfglass 12 Comments

We’re impressed to see the continued flow of new and interesting ways to utilize 3D printing despite its years in the hacker limelight. At the 2020 Hackaday Remoticon [Billie Ruben] came to us from across the sea to demonstrate how to use 3D printing and fabric, or other flexible materials, to fabricate new and interesting creations. Check out her workshop below, and read on for more detail about what you’ll find.

The workshop is divided into two parts, a hands-on portion where participants execute a fabric print at home on their own printer, and a lecture while the printers whirr away describing ways this technique can be used to produce strong, flexible structures.

The technique described in the hands on portion can be clumsily summarized as “print a few layers, add the flexible material, then resume the printing process”. Of course the actual explanation and discussion of how to know when to insert the material, configure your slicer, and select material is significantly more complex! For the entire process make sure to follow along with [Billie]’s clear instructions in the video.

The lecture portion of the workshop was a whirlwind tour of the ways which embedded materials can be used to enhance your prints. The most glamourous examples might be printing scales, spikes, and other accoutrement for cosplay, but beyond that it has a variety of other uses both practical and fashionable. Embedded fabric can add composite strength to large structural elements, durable flexibility to a living hinge, or a substrate for new kinds of jewelry. [Billie] has deep experience in this realm and she brings it to bear in a comprehensive exposition of the possibilities. We’re looking forward to seeing a flurry of new composite prints!

Hack Together Your Own Bat Signal

July 11, 2020 by Orlando Hoilett 27 Comments

Bats use echolocation to see objects in front of them. They emit an ultrasonic pulse around 20 kHz (and up to 100 kHz) and then sense the pulses as they reflect off an object and back to the bat. It’s the same type of mechanism used by ultrasonic proximity sensors for object-avoidance. Humans (except perhaps the very young ones) can’t hear the ultrasonic pulses since the frequency is too high, but an inexpensive microphone in a simple bat detector could. As it turns out bat detectors are available off the shelf, but where’s the fun in that? So, like any good hacker, [WilkoL] decided to build his own.

[WilkoL’s] design is composed primarily of an electret microphone, microphone preamplifier, CD4040 binary counter, LM386 audio amplifier, and a speaker. Audio signals are analog and their amplitudes vary based on how close the sound is to the microphone. [WilkoL] wanted to pick up bat sounds as far away as possible, so he cranked up the gain of the microphone preamplifier by quite a bit, essentially railing the amplifiers. Since he mostly cares about the frequency of the sound and not the amplitude, he wasn’t concerned about saturating the transistor output.

The CD4040 then divides the signal by a factor of 16, generating an output signal within the audible frequency range of the human ear. A bat signal of 20 kHz divides down to 1.25 kHz and a bat signal of up to 100 kHz divides down to 6.25 kHz.

He was able to test his bat detector with an ultrasonic range finder and by the noise generated from jingling his keychain (apparently there are some pretty non-audible high-frequency components from jingling keys). He hasn’t yet been able to get a recording of his device picking up bats. It has detected bats on a number of occasions, but he was a bit too late to get it on video.

Anyway, we’re definitely looking forward to seeing the bat detector in action! Who knows, maybe he’ll find Batman.

Continue reading “Hack Together Your Own Bat Signal” →

3D Printed DIY Neuralyzer

June 19, 2020 by Orlando Hoilett 3 Comments

We agree with you. We can never have enough cosplay hacks. And the ones that include some electronics element definitely have a special place in our hearts. That’s why when we ran across [Maddogg0’s] 3D printed Neuralyzer on Instructables, we knew we had to share.

You may recall [How to make’s] DIY Neuralyzer that we featured a few weeks ago which required more of a metal-working approach. [Maddogg0’s] design might be a bit more convenient for those of you that have a 3D printer, but no machine shop.

We love the elegant simplicity of [Maddogg0’s] design. The entire enclosure is printed in two halves that are held together by magnets. One half of the enclosure houses a single coin cell battery and a tiny circuit board for holding the LEDs in place, really giving the Neuralyzer some shine. In true maker fashion, [Maddogg0] released the necessary design files on TinkerCAD so anyone can reuse, remix, and reshare.

Whichever design you fancy, [Maddogg0’s] or [How to make’s], be careful not to point the Neuralyzer at yourself and always remember to wear your sunglasses!

PCB Jewelry Never Looked So Good

May 16, 2020 by Orlando Hoilett 8 Comments

[Gautchh] wanted to make something nice for his girlfriend. Being the DIY enthusiast he is, he thought a hand-made gift would resonate with her better than something he could pick up from the store. Enter NeckLight, a glow in the dark PCB necklace. He was first inspired by another project he ran across on Instructables, then decided to put his own little spin on the design. It’s cool how that works. Interestingly enough, it was his first time using Fusion 360, but you probably wouldn’t know that if you took a look at the results.

Aside from soldering, the trickiest part of this project was trying to get the LED intensities just right. [Gautchh] found the best way to do this was experimentally by testing each LED color with a series of resistors. He wanted to ensure he could get the color intensity and the LED current just right. Finally, with a touch of acetone, he was done (though he might want to try some alternatives to acetone next time).

[Gautchh] also thinks that this project would be a really nice way for beginners to learn surface mount (SMD) soldering. We’ve seen a few cool SMD LED projects before. Who could forget those competitive soldering challenges over at DEF CON?

Anyway. Thanks, [Gautchh]. We hope your girlfriend, and your dog, enjoyed their gifts.