Wire ECM built from an Ender 3

Simple Mods Turn 3D Printer Into Electrochemical Metal Cutter

We’re not aware of any authoritative metrics on such things, but it’s safe to say that the Ender 3 is among the most hackable commercial 3D printers. There’s just something about the machine that lends itself to hacks, most of which are obviously aimed at making it better at 3D printing. Some, though, are aimed in a totally different direction.

As proof of that, check out this Ender 3 modified for electrochemical machining. ECM is a machining process that uses electrolysis to remove metal from a workpiece. It’s somewhat related to electric discharge machining, but isn’t anywhere near as energetic. [Cooper Zurad] has been exploring ECM with his Ender, which he lightly modified by replacing the extruder with a hypodermic needle electrode. The electrode is connected to a small pump that circulates electrolyte from a bath on the build platform, while a power supply connects to the needle and the workpiece. As the tool traces over the workpiece, material is electrolytically removed.

The video below is a refinement of the basic ECM process, which [Cooper] dubs “wire ECM.” The tool is modified so that electrolyte flows down the outside of the needle, which allows it to enter the workpiece from the edge. Initial results are encouraging; the machine was able to cut through 6 mm thick stainless steel neatly and quickly. There does appear to be a bit of “flare” to the cut near the bottom of thicker stock, which we’d imagine might be mitigated with a faster electrolyte flow rate.

If you want to build your own Ender ECM, [Cooper] has graciously made the plans available for download, which is great since we’d love to see wire ECM take off. We’ve covered ECM before, but more for simpler etching jobs. Being able to silently and cleanly cut steel on the desktop would be a game-changer.

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Battery Of The Future, Now Buildable Yourself

In theory, batteries and capacitors are fairly simple. One stores energy chemically and the other stores energy in an electric field. In practice though, building an energy storage device that has a practical amount of energy density is delicate, complex work. But if you have access to a few chemical compounds it’s actually not too difficult to produce useful batteries and electrolytic capacitors with the use of ionic liquids.

Ionic liquids are conductive liquids with a few other important qualities. Almost all of the ones shown can be built with relatively common compounds, and most of the products have advantageous physical qualities, making them stable and relatively safe for use. With some equipment found in a chemistry lab it’s possible to produce a wide variety of these liquids without too much hassle (although one method outlined uses an inert gas chamber), and from there batteries and capacitors can be built by allowing the ionic liquids to be absorbed into the device.

The video below shows the production of several of these devices and then illustrates their effects by running a small LED light. While they’re probably not going to be used to create DIY electric cars anytime soon, the production and improvement of atypical energy storage devices will be the key to a large part of the energy needs of society now and into the future, especially aluminum batteries like these.

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Machining Without Machines

It’s a luxury to be able to access a modern machine shop, complete with its array of lathes, mills, and presses. These tools are expensive though, and take up a lot of space, so if you want to be able to machine hard or thick metals without an incredible amount of overhead you’ll need a different solution. Luckily you can bypass the machines in some situations and use electricity to do the machining directly.

This project makes use of a process known as electrochemical machining and works on the principle that electricity passed through an electrolyte solution will erode the metal that it comes in contact with. With a well-designed setup, this can be used to precisely machine metal in various ways. For [bob]’s use this was pretty straightforward, since he needed to enlarge an existing hole in a piece of plate steel, so he forced electrolyte through this hole while applying around half an amp of current in order to make this precise “cut” in the metal, avoiding the use of an expensive drill press.

There are some downsides to the use of this process as [bob] notes in his build, namely that any piece of the working material that comes in contact with the electrolyte will be eroded to some extent. This can be mitigated with good design but can easily become impractical. It’s still a good way to avoid the expense of some expensive machining equipment, though, and similar processes can be used for other types of machine work as well.

Top Off A Dry Electrolytic

Making a capacitor is pretty easy. Just get two conductors close together. The bigger area you can get and the closer you can get them, the bigger the capacitor you can make. [BigClive] found some fake capacitors that were supposed to be very high value, but weren’t. Taking them apart revealed the capacitors didn’t have the electrolyte inside that gives these units both their name and their high values. What did he do? Mixed up some electrolyte and filled them back up to see what would happen. You can see the video below.

Electrolytic capacitors have a secret weapon to get the two electrodes as close as possible to each other. The electrolyte forms a very thin insulating layer on one electrode and the capacitance is between the conductive fluid and that electrode — not between the two electrodes. This allows for a very narrow gap between the conductors and explains why a small electrolytic can have a much greater capacitance than most other technologies in similar form factors.

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Amiga Repairs Put One Tough Little Machine Back In Service

Returning a piece of retro hardware to factory condition is generally a labor of love for the restorationist. A repair, on the other hand, is more about getting a piece of equipment back into service. But the line between repair and restoration is sometimes a fine one, with the goals of one bleeding over into the other, like in this effort to save an otherwise like-new Amiga 2000 with a leaky backup battery.

Having previously effected emergency repairs to staunch the flow of electrolyte from the old batteries and prevent further damage, [Retromat] entered the restoration phase of the project. The creeping ooze claimed several caps and the CPU socket as it spread across the PCB, but the main damage was to the solder resist film itself. In the video below you can clearly see flaky, bubbly areas in the mask where the schmoo did its damage.

Using a fiberglass eraser, some isopropyl alcohol, and far more patience than we have, [Retromat] was able to remove the damaged resist to reveal the true extent of the damage below. Thankfully, most of the traces were still intact; only a pair of lines under the CPU socket peeled off as he was removing it. After replacing them with fine pieces of wire, replacing the corroded caps and socket, and adding a coin-cell battery holder to replace the old battery, the exposed traces were coated with a varnish to protect them and the machine was almost as good as new.

Amigas were great machines in their day and launched more than one business. They’ve proved their staying power too, some even in mission-critical roles.

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Getting The Lead Out Of Lithium Battery Recycling

When that fateful morning comes that your car no longer roars to life with a quick twist of the key, but rather groans its displeasure at the sad state of your ride’s electrical system, your course is clear: you need a new battery. Whether you do it yourself or – perish the thought – farm out the job to someone else, the end result is the same. You get a spanking new lead-acid battery, and the old one is whisked away to be ground up and turned into a new battery in a nearly perfect closed loop system.

Contrast this to what happens to the battery in your laptop when it finally gives up the ghost. Some of us will pop the pack open, find the likely one bad cell, and either fix the pack or repurpose the good cells. But most dead lithium-based battery packs are dropped in the regular trash, or placed in blue recycling bins with the best of intentions but generally end up in the landfill anyway.

Why the difference between lead and lithium batteries? What about these two seemingly similar technologies dictates why one battery can have 98% of its material recycled, while the other is cheaper to just toss? And what are the implications down the road, when battery packs from electric vehicles start to enter the waste stream in bulk?

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Morbid Battery Uses Blood Electrolyte

Building a battery out of common household products is actually pretty simple. All that is required is two dissimilar metals and some sort of electrolyte to facility the transfer of charge. A popular grade school science experiment demonstrates this fairly well by using copper and zinc plates set inside a potato or a lemon. Almost anything can be used as the charge transfer medium, as [dmitry] demonstrates by creating a rather macabre battery using his own blood.

The battery was part of an art and science exhibition but it probably wouldn’t be sustainable on a large scale, as it took [dmitry] around 18 months to bank enough blood to make a useful battery. Blood contains a lot of electrolytes that make it perfect for this application though, and with the addition of the copper anode and aluminum cathode [dmitry] can power a small speaker which plays a sound-generating algorithm that frankly adds a very surreal element to the art installation.

While we can’t recommend that you try to build one of these batteries on your own without proper medical supervision, the video of the art piece is worth checking out. We’ve seen a few other hacks that involve blood, but usually they are attempting to use it for its intended purpose rather than as an alternative energy source.