3D Printed Engine Gets Carburetor

August 30, 2023 by Bryan Cockfield 14 Comments

3D printed materials have come a long way in the last decade or so as printers have become more and more mainstream. Printers can use all kinds of different plastics with varying physical characteristics, and there are even printers now for other materials like concrete and metal. But even staying within the realm of the plastic printer can do a lot of jobs you might not expect. [Camden Bowen] recently 3D printed a single-piston engine which nearly worked, and is back with some improvements to it thanks to a small carburetor.

The carburetor itself isn’t 3D printed (although not from lack of trying) — it’s on loan from a weed eater, and is helping to solve a problem with the fuel-air mixture of his original design. Switching from butane to a liquid fuel also solved some problems as well, and using starter fluid also helped to kick off the ignition. Although it ran for a short period of time over several starts, the valve train suffered some damage with the exhaust valves melting in place to the head. This is actually a problem common to any internal combustion engine like this, especially if the fuel-air mixture is too lean, there’s incomplete combustion, the valves aren’t adjusted properly, or any number of other problems. In this case it seems to have been caused by improper engine timing.

It’s actually noteworthy though that the intake valves weren’t burned, meaning that if the engine can be tuned to allow for complete combustion before the exhaust gasses leave the combustion chamber, the plastic 3D printed head and valve train will likely survive much longer operational periods. We’ll certainly look forward to the next iteration of this engine build to see if that’s the case. If 3D printed piston engines aren’t your speed, though, take a look at this jet engine which uses a 3D printed compressor.

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Broken Genes And Scrambled Proteins: How Radiation Causes Biological Damage

January 24, 2023 by Dan Maloney 31 Comments

If decades of cheesy sci-fi and pop culture have taught us anything, it’s that radiation is a universally bad thing that invariably causes the genetic mutations that gifted us with everything from Godzilla to Blinky the Three-Eyed Fish. There’s a kernel of truth there, of course. One only needs to look at pictures of what happened to Hiroshima survivors or the first responders at Chernobyl to see extreme examples of what radiation can do to living tissues.

But as is usually the case, a closer look at examples a little further away from the extremes can be instructive, and tell us a little more about how radiation, both ionizing and non-ionizing, can cause damage to biochemical structures and processes. Doing so reveals that, while DNA is certainly in the crosshairs for damage by radiation, it’s not the only target — proteins, carbohydrates, and even the lipids that form the membranes within cells are subject to radiation damage, both directly and indirectly. And the mechanisms underlying all of this end up revealing a lot about how life evolved, as well as being interesting in their own right.

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Acid-Damaged Game Boy Restored

January 17, 2022 by Bryan Cockfield 11 Comments

The original Game Boy was the greatest selling handheld video game system of all time, only to be surpassed by one of its successors. It still retains the #2 position by a wide margin, but even so, they’re getting along in years now and finding one in perfect working condition might be harder than you think. What’s more likely is you find one that’s missing components, has a malfunctioning screen, or has had its electronics corroded by the battery acid from a decades-old set of AAs.

That latter situation is where [Taylor] found himself and decided on performing a full restoration on this classic. To get started, he removed all of the components from the damaged area so he could see the paths of the traces. After doing some cleaning of the damage and removing the solder mask, he used 30 gauge wire to bridge the damaged parts of the PCB before repopulating all of the parts back to their rightful locations. A few needed to be replaced, but in the end the Game Boy was restored to its former 90s glory.

This build is an excellent example of what can be done with a finely tipped soldering iron while also being a reminder not to leave AA batteries in any devices for extended periods of time. The AA battery was always a weak point for the original Game Boys, so if you decide you want to get rid of batteries of any kind you can build one that does just that.

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Tensions High After Second Failed Cable At Arecibo

November 11, 2020 by Tom Nardi 45 Comments

Today we’re sad to report that one of the primary support cables at the Arecibo Observatory has snapped, nudging the troubled radio telescope closer to a potential disaster. The Observatory’s 300 meter reflector dish was already badly in need of repairs after spending 60 years exposed to the elements in Puerto Rico, but dwindling funds have made it difficult for engineers to keep up. Damage from 2017’s Hurricane Maria was still being repaired when a secondary support cable broke free and smashed through the dish back in August, leading to grave concerns over how much more abuse the structure can take before a catastrophic failure is inevitable.

The situation is particularly dire because both of the failed cables were attached to the same tower. Each of the remaining cables is now supporting more weight than ever before, increasing the likelihood of another failure. Unless engineers can support the dish and ease the stress on these cables, the entire structure could be brought down by a domino effect; with each cable snapping in succession as the demands on them become too great.

Workers installing the reflector’s mesh panels in 1963.

As a precaution the site has been closed to all non-essential personnel, and to limit the risk to workers, drones are being used to evaluate the dish and cabling as engineers formulate plans to stabilize the structure until replacement cables arrive. Fortunately, they have something of a head start.

Back in September the University of Central Florida, which manages the Arecibo Observatory, contacted several firms to strategize ways they could address the previously failed cable and the damage it caused. Those plans have now been pushed up in response to this latest setback.

Unfortunately, there’s still a question of funding. There were fears that the Observatory would have to be shuttered after Hurricane Maria hit simply because there wasn’t enough money in the budget to perform the relatively minor repairs necessary. The University of Central Florida stepped in and provided the funding necessary to keep the Observatory online in 2018, but they may need to lean on their partner the National Science Foundation to help cover the repair bill they’ve run up since then.

The Arecibo Observatory is a unique installation, and its destruction would be an incredible blow for the scientific community. Researchers were already struggling with the prospect of repairs putting the powerful radio telescope out of commission for a year or more, but now it seems there’s a very real possibility the Observatory may be lost. Here’s hoping that teams on the ground can safely stabilize the iconic instrument so it can continue exploring deep space for years to come.

Patience Beats Rage-Quit In Shattered Xbox Controller Repair

September 19, 2020 by Brian McEvoy 18 Comments

There are negative-one hacks to this project. Someone lost at their game, lost their temper, then raged at their Xbox controller with some horsepower. The result is that [Taylor Burley] gets a free controller with a non-responsive joystick out of the deal, and since he had nothing to lose, he decided to heat up the iron and bring the controller back to life.

The majority of the project is told in pictures and through the narration in the video below. In removing the joystick, [Taylor] opts for the technique of doping the connections with fresh solder (we assume containing lead for easier melting) before reaching for the desoldering wick. The diagnosis stage is brief because when the joystick lifts away, the PCB falls apart into two separate pieces! The next step was to glue the two halves together with cyanoacrylate to get into the nooks and crannies, then epoxy to provide structure. Solder bridges were not going to jump that gap, so he used 30ga wire and attached it wherever he could scrape away some solder mask. Best of all, it worked when he reattached the joystick. Job well done.

Xbox controllers are not a scarce commodity, so people do not spend their idle hours fixing them, but not many people can claim experience. Maybe someday the stakes will be higher and he will have the courage to repair vintage electronics. We won’t rant on how things aren’t built to last, and how we don’t train people to fix things. Today, we want to focus on someone who used their time to repair and learn.

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See The Damage 250-Pound Combat Robots Get

March 9, 2020 by Donald Papp 14 Comments

Combat robots have been a thing for a while, but we don’t normally get a close look at the end results of the sort of damage they can both take and deal out. [Raymond Ma] spent time helping out with season four of BattleBots and wrote about the experience, as well as showed several pictures of the kind of damage 250-pound robots can inflict upon each other. We’ve embedded a few of them here, but we encourage you to read [Raymond]’s writeup and see the rest for yourself.

The filming for a season of BattleBots is done in a relatively short amount of time, which means the pacing and repair work tends to be more fast and furious than slow and thoughtful. [Raymond] says that it isn’t uncommon for bots, near the end of filming, to be held together with last-minute welds, wrong-sized parts, and sets of firmly-crossed fingers. This isn’t because the bots themselves are poorly designed or made; it’s because they can get absolutely wrecked by the forces at play.

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Walk It Off, Healing Robots

September 29, 2018 by Brian McEvoy 4 Comments

For many of us, our first robots, or technical projects, were flimsy ordeals built with cardboard, duct tape, and high hopes. Most of us grow past that scene, and we learn to work supplies which require more than a pair of kitchen scissors. Researchers at Carnegie Mellon University and Iowa State University have made a material which goes beyond durable, it can heal itself when wounded. To a small robot, a standard hole puncher is a dire assailant, but the little guy in the video after the break keeps hopping around despite a couple of new piercings.

The researcher’s goal is to integrate this substance into bio-inspired robots which may come to harm in the field. Fish-like robots could keep swimming after a brush with a bit of coral or a curious predator. Robot snakes could keep slithering after a fall or a gravel road.

Of course, robotic simulacrums are not the only ones who can benefit from healing circuitry. Satellites are prey to punctures from errant space debris.

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