Bare Bones Vacuum Forming, Just Add Plastic Plates

September 14, 2023 by Donald Papp 16 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.

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A scale model of the International Space Station

This Model Mimics The International Space Station

September 4, 2023 by Julian Scheffers 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.
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A Bubble Machine Built From Scrap

August 20, 2023 by Al Williams 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.

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DIY Eye Tracking For VR Headsets, From A To Z

August 5, 2023 by Donald Papp 4 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.

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Open-Source Cell Phone Based On ESP32

August 3, 2023 by Bryan Cockfield 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!

Making Your Own VR Headset? Consider This DIY Lens Design

August 1, 2023 by Donald Papp 11 Comments

Lenses are a necessary part of any head-mounted display, but unfortunately, they aren’t always easy to source. Taking them out of an existing headset is one option, but one may wish for a more customized approach, and that’s where [WalkerDev]’s homebrewed “pancake” lenses might come in handy.

Engineering is all about trade-offs, and that’s especially true in VR headset design. Pancake lenses are compact units that rely on polarization to bounce light around internally, resulting in a very compact assembly at the cost of relatively poor light efficiency. That compactness is what [WalkerDev] found attractive, and in the process discovered that stacking two different Fresnel lenses and putting them in a 3D printed housing yielded a very compact pancake-like unit that gave encouraging results.

This project is still in development, and while the original lens assembly is detailed in this build log, there are some potential improvements to be made, so stay tuned if you’re interested in using this design. A DIY headset doesn’t mean you also must DIY the lenses entirely from scratch, and this option seems economical enough to warrant following up.

Want to experiment with mixing and matching optics on your own? Not only has [WalkerDev]’s project shown that off-the-shelf Fresnel lenses can be put to use, it’s in a way good news that phone-based VR is dead. Google shipped over 10 million cardboard headsets and Gear VR sold over 5 million units, which means there are a whole lot of lenses in empty headsets laying around, waiting to be harvested and repurposed.

Behold A DIY VR Headset Its Creator Will “Never” Build Again

July 10, 2023 by Donald Papp 13 Comments

Unsatisfied with commercial VR headset options, [dragonskyrunner] did what any enterprising hacker would: gathered parts over time and ultimately made their own. Behold the Hades Widebody (HWD), a DIY PC VR headset that aims for a wide field of view and even manages to integrate some face and eye tracking.

The Fresnel elements hugging the primary lenses provide a way of extending the display into the wearer’s peripheral vision.

[dragonskyrunner] is — and we quote — “NEVER building one of these again.” The reason is easily relatable to anyone who has spent a lot of time and effort creating something special: it does the job it was created for, but it also has limitations and is a lot of work. If one were to do it all over again, there would be a host of improvements and changes to consider. But one won’t be doing it all over again any time soon because it’s done now.

The good news is that [dragonskyrunner] made an effort to document things, so there is at least a parts list and enough details for any suitably motivated hacker to replicate the work and perhaps even put their own spin on it.

The Hades Widebody has a dual-lens arrangement and wide displays that aim to provide a wider field of view than most setups allow. There’s a main lens in front of the user’s eyes and a cut Fresnel lens providing a sort of extension to the side. [dragonskyrunner] claims that while there is certainly not a seamless transition between the lens elements, it does a better job than an Ambilight at providing a sense of visuals extending into the wearer’s peripheral vision.

The DIY spirit of making a piece of hardware to suit one’s own needs is exactly the sort of thing that would fit into our 2023 Cyberdeck content, and while a headset by itself isn’t quite enough to qualify (devices must have some form of usable input and output), it just might get those creative juices flowing.