diy

397 Articles

USB-C For Hackers: Build Your Own PSU

October 12, 2023 by 43 Comments

What if you wanted to build your own USB-C PSU? Good news – it’s easy enough! If you ever wanted to retrofit a decent DC PSU of yours to the USB-C standard, say, you got a Lenovo/HP/Dell 19V-20V charger brick and you’ve ever wished it were USB-C, today is the day when we do exactly that. To be fair, we will cheat a bit – but only a tiny bit, we won’t be deviating too much from the specification! And, to begin with, I’ll show you some exceptionally easy ways that you can turn your DC PSU into a USB-C compatible one, with a simple module or a few.

Turning a 20 V PSU into a USB-C PSU feels natural if you want to charge a laptop – those tend to request 20 V from a USB-C PSU anyway, so what’s the big deal? However, you can’t just put 20 V onto a USB-C connector – you have to add a fair bit of extra logic to make your newly christened USB-C PSU safe to use with 5 V devices, and this logic also requires you go through a few extra steps before 20 V appears on VBUS. Any USB-C PSU has to output 5 V first and foremost whenever a device is connected, up until a higher voltage is negotiated digitally, and the PSU may only switch to a higher voltage output when it’s requested to do so.

Now, for that, a PSU offers a list of profiles, and we looked into those profiles in the Replying PD article – each profile is four bytes that contain information about the profile voltage, maximum current that the device may draw at that voltage, and a few other details. For a PSU to be USB-C compliant, the USB-C specification says that, in addition to 5 V, you may also offer 9 V, 15 V, and 20 V.

Also, the specification says that if a PSU supports certain in-spec voltage like 15 V, it’s also required by the spec to offer all of the spec-defined voltages below the maximum one – for 15 V, that also requires supporting 9 V. Both of these are UX requirements, as opposed to technical requirements – it’s easier for device and PSU manufacturers to work with a small set of pre-defined voltages that majority of the chargers will support, but in reality, you can actually offer any voltage you want in the PSU advertisement; at worst, a device is going to refuse and contend with slowly charging from the 5 V output that you’re required to produce.

I’d like to walk you through how off-the-shelf USB-C PSUs work, all of the options you can use to to create one, and then, let’s build our own USB-C PSU from scratch! Continue reading “USB-C For Hackers: Build Your Own PSU” →

These DIY Super Headphones Take Sound Seriously

October 1, 2023 by 23 Comments

[Pete Lewis] from SparkFun takes audio and comfort seriously, and recently shared details on making a customized set of Super Headphones, granting quality sound and stereo ambient passthrough, while providing hearing protection at the same time by isolating the wearer from the environment.

Such products can be purchased off the shelf (usually called some variant of “electronic hearing protection”), but every hacker knows nothing beats some DIY to get exactly the features one wants. After all, off-the-shelf solutions are focused on hearing protection, not sound quality. [Pete] also wanted features like the ability to freely adjust how much ambient sound was mixed in, as well as the ability to integrate a line-level audio source or Bluetooth input.

Early prototype of Super Headphones (click to enlarge)

On the surface the required components are straightforward, but as usual, the devil is in the details. Microphone selection, for example, required a lot of testing. A good microphone needed to be able to deal with extremely loud ambient sounds without distortion, yet still be sensitive enough to be useful. [Pete] found a good solution, but also muses that two sets of microphones (one for loud environments, and one for quieter) might be worth a try.

After several prototypes, the result is headphones that allow safe and loud band practice in a basement as easily as they provide high-quality music and situational awareness while mowing the lawn. Even so, [Pete]’s not done yet. He’s working on improving comfort by using photogrammetry to help design and 3D print custom-fitted components.

Bare Bones Vacuum Forming, Just Add Plastic Plates

September 14, 2023 by 15 Comments

Vacuum forming is a handy thing to be able to do, and [3DSage] demonstrates how to do a bare-bones system that can form anything smaller than a dinner plate with little more than a 3D printed fitting to a vacuum cleaner, a heat gun, and a trip to the dollar store.

Plastic plates from the dollar store make excellent forming sheets, and in a variety of colors.

The 3D printed piece is a perforated table that connects to a vacuum cleaner hose, and [3DSage] mentions elsewhere that he tried a few different designs and this one worked the best. A cardboard box makes an expedient stand. The object being molded goes on the table, and when the vacuum is turned on, air gets sucked down into the holes.

As for the thermoforming itself, all that takes is some cheap plastic plates and a heat gun. Heat the plastic until it begins to droop, then slap it down onto the vacuum table and watch the magic happen. Using plastic plates like this is brilliant. Not only are they economical, but their rim serves as a built-in handle and helps support the sagging plastic.

Thermoforming plastic on a 3D-printed vacuum table and using 3D-printed molds definitely isn’t a system that will be cranking parts out all day long, but as long as one allows time for everything to cool off in between activations, it’ll get the job done. Nylon will hold up best but even PLA can be serviceable.

Watch it in action in the video embedded below. The video is actually about [3DSage] making adorable Game Boy themed s’mores, but here’s a link to the exact moment the vacuum forming part happens.

Continue reading “Bare Bones Vacuum Forming, Just Add Plastic Plates” →

A scale model of the International Space Station

This Model Mimics The International Space Station

September 4, 2023 by 6 Comments

It’s not an overstatement to say that the International Space Station (ISS for short) is an amazing feat of engineering, especially considering that it has been going for over two decades. The international collaboration isn’t just for the governments, either, as many images, collected data and even some telemetry have been made available to the public. This telemetry inspired [Bryan Murphy] and his team to create the ISS MIMIC, a 1:100 scale model of the ISS that reflects its space counterpart.

The model, covered by [3D Printing Nerd] after the break, receives telemetry from the real ISS and actually reflects the orientation of the solar panels accordingly! It also uses this entirely public information to show other things like battery charge level, power production, position above the earth and more on a display. An extra detail we appreciated is the LEDs near the solar panels, which are red, blue or white to indicate using battery, charging battery and full battery respectively. The ISS orbits the earth once every 90 minutes, which can be seen by the LEDs changing color as the ISS enters the shadow of the earth, or exits it.

What could you do to make this better you might ask? Make the it open-source of course! The ISS MIMIC is fully open-source and uses common tools like 3D printing with PLA, Raspberry Pis and Arduinos to make it as accessible as possible for education (and hackers). Naturally, the goal of this project is to educate, which is why it’s open-source and aims to teach programming, electronics, mechatronics and problem solving.

Video after the break.
Continue reading “This Model Mimics The International Space Station” →

A Bubble Machine Built From Scrap

August 20, 2023 by 10 Comments

Not every project has to be an AI-powered particle accelerator using lasers. Sometimes simple projects can be very satisfying, and a simple project can be a great gateway to introduce a friend or a child to our hacker ways. That’s why we noticed [Crazy Science’s] bubble machine upcycled from a CD and a water bottle. It isn’t likely to figure in anyone’s Ph.D. dissertation any time soon, but that isn’t the point

Once you see the pictures, you can probably figure out how to build it. For extra points, consider scrounging everything from stuff you already have. We were curious about drilling holes in the CD as we’d imagine they’d crack with an ordinary drill bit. Apparently, a soldering iron will pierce the disk, but we would advise doing that in a well-ventilated area.

Continue reading “A Bubble Machine Built From Scrap” →

DIY Eye Tracking For VR Headsets, From A To Z

August 5, 2023 by 3 Comments

Eye tracking is a useful feature in social virtual reality (VR) spaces because it really enhances presence and communication when one’s avatar has a realistic gaze. Most headsets lack this feature, but EyeTrackVR has a completely open source solution ready for anyone willing to put it together.

Camera is visible in lower right corner.

EyeTrackVR is a combination of hardware, software, and 3D printable mounts for attaching a pair of microcontroller boards, cameras, and IR LEDs to just about any existing VR headset out there. An ESP32-based board and tiny camera module watches each eyeball, and under IR illumination the pupil presents as an easily-identified round black area. Software takes care of turning the camera’s view of the pupil into a gaze direction value that can be plugged into other software.

The project is still under active development, but in its current state is perfectly suitable for creating a functional system that can integrate into a variety of existing headsets with printed mounting brackets. Interested? Check out the intro and if it sounds up your alley, dive into the build guide which spells out everything you need to know. Check out the video below for a demo of EyeTrackVR working in VRChat, along with an overview of software support.

We’ve seen headsets built to custom specs that integrate eye tracking, but even if one is repackaging an existing headset that’s a perfect opportunity to include this feature.

Continue reading “DIY Eye Tracking For VR Headsets, From A To Z” →

Open-Source Cell Phone Based On ESP32

August 3, 2023 by 40 Comments

Over the past decade or so, smartphones have exploded in popularity and seamlessly integrated themselves into nearly every aspect of most people’s lives. Although that comes with a few downsides as well, with plenty of people feeling that the smart phone makes it a little too easy to waste time and looking to switch to something simpler, like an older-style flip phone. If this style of phone is more your speed, take a look at this DIY cell phone which takes care of everything a phone really needs to do. (Google Translate from French)

The phone uses an ESP32 at its core, with a SIM800L GSM modem to interact with the cell network, including retrieving the system time. A small battery is included as well as all of the support circuitry for charging it as well as a USB interface that can communicate to a PC. The operating system for the phone is built from the ground up as well, with a touch screen interface allowing the user to make phone calls, send text messages, store contacts, and a few other basic features. There’s also a GPS application though, allowing the phone to know basic location information.

Another perk of this device is that its creator, [Gabriel], made the design schematics, print files for the case, and the operating system software completely open source for anyone to build this phone on their own. Everything is available on the project’s GitHub page. It’s a fairly remarkable achievement, especially considering [Gabriel] is only 16. And, if you’re not one to eschew modern smart phone technology there are some DIY smart phones available to build as well.

Thanks to [come2] for the tip!