DIY Magnet Handling Tool Puts An End To Placement Errors

January 14, 2023 by Donald Papp 10 Comments

I’m sure we can all agree that the worst time to find out a magnet is the wrong way around is after glue has been applied. With that in mind, [erick.siders] created the parametric Magnet Placer tool.

Color-coded tools, one for each polarity.

Picking up and placing magnets into assemblies can be an error-prone process, because magnet polarity cannot be directly identified or sensed by either sight or fingertips. This tool helps by acting a lot like a suction pickup tool — press the plunger down, and a magnet can be picked up, release the plunger, and the magnet lets go. Simple, and effective.

Since the tool is polarity-dependent (depending on which orientation the pickup magnet is mounted into the internal plunger), [erick.siders] suggests printing two tools and color-coding them. That way, one can choose the right tool based on the situation and be confident that the magnets are right-side-up, every time.

The tools use a long metric bolt, a magnet, and a spring, but none of those parts are particularly critical. We also love the way that the end result has no gaps or openings into the moving parts, which means nothing can get caught on or inside anything during use or storage.

It’s a parametric design and the CAD files (in both Fusion 360 and STEP flavors) are provided, so modification should be a breeze. And if you happen to be using PrusaSlicer, remember you can now drop STEP format files directly in for slicing.

A Hacker’s Christmas Story

December 24, 2022 by Elliot Williams 11 Comments

Twas the night before Christmas, and because I decided to make everyone’s presents myself this year, I’m still working like mad to get everything done before the big deadline. Why do I do this to myself? Well, partly because I enjoy the process.

My wife had this idea that we can make the older folks some fun decorative blinky things, and picked some motives. My son then drew them out on paper, and I scanned those drawings in and traced them over in CAD. We then cut the shapes out of wood on the CNC router, which turned out to be incredibly successful. (Now that I’ve done it, I wouldn’t be surprised if all of those “quirky” decorative objects that the Swedish flat-packers sell aren’t initially sketched out by third graders.)

Then my son painted them, and it’s my job to insert the twinkling. I bought some of those three-wire “fairy lights” for the purpose, and they’re really fun to hack on. They’re like WS2812s, only instead of using four pins and shifting the data downstream, they’re on a bus, each with a hard-coded address – they know where they are in the string and each LED only listens for the Nth set of 24 bits. This means sending 200 color codes just to light up the 4 LEDs in Aunt Micki’s decorative tree, but so be it.

Last stop, and still to do as of the 23rd, route out some kind of wooden battery case, wedge in the LiPo and the charging circuits, and solder on an on/off switch. It’s down to the last minute, but isn’t that always the way?

Definitely would have been easier just to order something online. But is that the spirit of giving? No! The DIY way brings the family together, gets me some quality time with the CNC machine, and tones up my FreeCAD skills. My son even looked over my shoulder as we were coding some of the LED animations. And nothing says Christmas like hand-coded blinkies.

Happy Holidays, y’all!

Supercon 2022: Sam Mulvey Shows You How To FM Radio

December 15, 2022 by Elliot Williams 19 Comments

Sam Mulvey built his own radio station in Tacoma, WA. Is there a better way to meld ham radio practice with a colossal number of DIY electrical and computer projects? Sam would say there isn’t one! This 45-minute talk is basically the lessons-learned review of setting up KTQA 95.3 – the radio station on the hill.

Sam starts out the talk by introducing you to LPFM. And maybe you didn’t know that there’s a special type of license issued by the US FCC allowing non-profit community radio stations up to 100 W, covering an radius of around 5 km. It’s like running a pirate radio station, but by jumping through a few legal hoops, made legal.

Trash on the Radio

Putting a radio station together on a budget requires a ton of clever choices, flexibility, and above all, luck. But if you’re willing to repair a busted CD player or turntable, scrounge up some used computers, and work on your own amplifiers, the budget doesn’t have to be the limiting factor.

Being cheap means a lot of DIY. For instance, Sam and friends made a custom console to support all the gear and hide all the wiring. Some hot tips from the physical build-out: painted cinderblocks make great studio monitor stands, and Cat-5 can carry two channels of balanced audio along with power, with sufficient isolation that it all sounds clean. Continue reading “Supercon 2022: Sam Mulvey Shows You How To FM Radio” →

DIY Heat-Set Insert Press Says Complicated = Comfort

October 23, 2022 by Donald Papp 17 Comments

Heat-set inserts are a great way to embed mechanically-strong, threaded parts into a 3D print. For installation, all that is required is an economical soldering iron; something most of us already have.

The carriage and counterweight use a v-wheel gantry, GT2 belt, and other common hardware.

That’s fine for a handful of occasional inserts, but when a large number need to be inserted reliably and cleanly, something a little more refined is called for. That’s where [virchow]’s threaded insert press design comes in. It adds 3D-printed parts to an aluminum extrusion frame to create a press that smoothly lowers a soldering iron directly up and down, with minimal effort by the user.

The holder for the soldering iron is mounted to a small v-wheel gantry that rides along the vertical extrusion. The gantry features a counterweight to take care of resetting the position of the iron. [Virchow] admits that the design could be considered unnecessarily complicated (hence the “UC” in the name) but on the other hand, there’s nothing like doing a hundred or so inserts to make one appreciate every bit of comfort and stability.

Heat-set inserts aren’t difficult to use, but a little technique goes a long way. Spend a few minutes reading Joshua Vasquez’s guide on the optimal way to use them in 3D-printed parts to make sure yours not only go in straight but end up looking great as well.

3D Printed Sorter Separates Spare Hex Nuts With A Shake

October 13, 2022 by Donald Papp 14 Comments

Got a pile of mixed hex nuts? Sort them in no time by printing [jonafriendj]’s nut sorter, which has options for pretty much any nut size you’d be after (it’s labeled metric, but actually includes Imperial sizes as well.)

Something to admire about the design is the handy little raised labels on each of the sieves, and the fact that all the parts print entirely without supports. Designing a part to play to a manufacturing method’s strengths (and avoid its weaknesses) is good DFM, or Design for Manufacturing.

With 3D printing being the boon that it is to workshops and hobbyists everywhere, it certainly pays to strive for good DFM, especially for designs meant to be shared with others. Sometimes good DFM takes a page from other manufacturing methods like injection molding, and we end up with things like using crush ribs on printed parts.

Want to see a demonstration of [jonafriendj]’s nut sorting design? Check out the short video embedded below the page break. If that leaves you wanting, take a look at a motorized, automated DIY solution.

Continue reading “3D Printed Sorter Separates Spare Hex Nuts With A Shake” →

DIy Arduino FM radio enclosure with the lid off, showing the electronics inside

DIY Arduino Due TEA5767 FM Radio

October 8, 2022 by Dave Walker 10 Comments

Older hackers will remember that a crystal set radio receiver was often one of the first projects attempted. Times have changed, but there’s still something magical about gathering invisible signals from the air and listening to the radio on a homemade receiver. [mircemk] has brought the idea right up to date by building an FM radio with an OLED display, controlled with a rotary encoder.

The design is fairly straightforward, based as it is on another project that [mircemk] found on another site, but the build looks very slick and would take pride of place on any hacker’s workbench. An Arduino Due forms the heart of the project, controlling a TEA5767 module, an SH1106 128×64 pixel OLED display and a rotary encoder. The sound signal is passed through an LM4811 headphone amplifier for private listening, and a PAM8403 Class D audio amplifier for the built-in loudspeaker. The enclosure is made from PVC panels, and accented with colored adhesive tape for style.

It’s easier than ever before to quickly put together projects like this by connecting pre-built modules and downloading code from the Internet, but that doesn’t mean it’s not a worthwhile way to improve your skills and make some useful devices like this one. There are so many resources available to us these days and standing on the shoulders of giants has always been a great way to see farther.

We’ve shown some other radio projects using Arduinos and the TEA5767 IC in the past, such as this one on a tidy custom PCB, and this one built into an old radio case.

Continue reading “DIY Arduino Due TEA5767 FM Radio” →

The Filamentmeter: For When You Absolutely Want To Count Every Meter Used

September 9, 2022 by Donald Papp 17 Comments

[ArduinoNmore] took an interesting approach to designing a counter intended to accurately display how many meters of filament a 3D printer has used. The Filamentmeter looks a little bit like a 3D printed handheld tally counter (or lap counter) but instead of a button to advance each digit, the readout represents how many meters of filament have gone through the extruder.

Driving the digit rotation from the extruder motor itself means that even retractions are accounted for.

At first glance it may look like there is a motor hidden inside, or that the device is somehow sensing the filament directly. But it’s actually the movement of the extruder motor that drives the device. A small spur gear attached to the printer’s extruder drives a series of gears that advance the digits. This means that retractions — small reverses of the extruder motor during printing — are properly accounted for in the total, which is a nice touch.

[ArduinoNmore] designed this for the Ender 3, and the Filamentmeter relies on a specific extruder design and orientation to work properly. Of course, since it’s 3D printed, modifying the design for your own purposes should be pretty straightforward.

Curious? The design is being sold for a few bucks, and there is a free test piece one can print and use to confirm whether the design will work before mashing the buy button. Non-free printable 3D models can be a world of buyer beware, but test pieces and solid documentation are good ways to give buyers confidence in your work.

The insides of the unit are really quite intricate, with a clockwork-type elegance to them. You can see it all in the short video, embedded below.

Continue reading “The Filamentmeter: For When You Absolutely Want To Count Every Meter Used” →