3D Printed Upgrade for Cheap Foam Glider

We know you’ve seen them: the big foam gliders that are a summertime staple of seemingly every big box retailer and dollar store in the world. They may be made by different companies or have slight cosmetic differences, but they all adhere to the basic formula: a long plastic bag containing the single-piece fuselage and two removable wings and a tail. Rip open the bag, jam the wings into the fuselage, and go see if you can’t get that thing stuck on a roof someplace.

But after you toss it around a few times, things start to get a little stale. Those of us in the Hackaday Collective who still retain memories of our childhood may even recall attempting to augment the glider with some strategically attached bottle rockets. But [Timothy Wright] has done considerably better than that. With the addition of a 3D printed “backpack”, he managed to add not only a motor to one of these foam fliers but an RC receiver and servos to move the control surfaces. The end result is a cheap and surprisingly capable RC plane with relatively little work required.

[Timothy] certainly isn’t claiming to be the first person to slap a motor on a foam glider to wring a bit more fun out of it, but his approach is very slick and of course has the added bonus of being available for other grownup kids to try thanks to the Creative Commons license he released the designs under. He mentions that variations in the different gliders might cause some compatibility issues, but with the generous application of some zip ties and tape, it should be good to go.

This particular hunk of foam might not set any altitude or distance records, and it certainly won’t be carrying you aloft, but it’s a pretty approachable summer project if you’ve got some RC gear laying around.

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Zen and the Art of Foam Core

Some of our pastimes are so deeply meditative that we lose ourselves for hours. Our hands seem to perform every step, and sequence like a pianist might recite her favorite song. If [Eric Strebel]’s voice and videos are any indications, working with foam core can have that effect.

Foam core is a staple of art stores, hobby stores, and office supply stores. It comes in different colors, but the universal trait is a sheet of foam sandwiched between a couple of layers of paper. This composition makes a versatile material which [Eric] demonstrates well in his advanced tutorial making a compound surface and later on a speaker mockup.

After the break, you can catch a couple of beginner tutorials which explain the differences between a slapdash foam core model, and one which will draw appreciation. Proper tools and thoughtful planning might be the biggest takeaways from the first two videos unless you count the Zen narration. The advanced videos, linked above, show some ingenious ways to use foam core like offset scoring, adjustable super-structures, and paper transfers.

Each video is less than ten minutes long, so if you just started your coffee break, you can complete a video right now. Or look at another 2D material turned into amazingness with a papercraft strandbeest, then step up your game with another look at vinyl cutters.
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Printing Without Supports!

If print supports have ever caused you grief, know that there’s an alternate printing method in the works. First: get yourself a vat of industrial gel in which to print.

Rapid Liquid Printing(RLP) is being developed in collaboration by Michigan-based company [Steelcase] and [Skylar Tibbits’] Self Assembly Lab at MIT. RLP is touting advantages over traditional 3D printing technology such as reduced print times, a higher quality print, and enabling larger scale prints — all without supports!

Working with rubber, plastic, or foam, the printing material is injected by nozzle into a basin of industrial gel. That gel suspends the print throughout the process without bonding to it and the finished product is simply lifted out of the gel and rinsed off. Shown off at the Design Miami event earlier this month, onlookers could pick up finished lampshades and tote bags after mere minutes.

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Things Learned From Hot Wire Cutting a Droid’s Body

One of [Bithead]’s passions is making Star Wars droids, and in the process of building the outer shell for one of them he decided to use hot wire foam cutting and make his own tools. Having the necessary parts on hand and having seen some YouTube videos demonstrating the technique, [Bithead] dove right in. Things didn’t go exactly to plan but happily he decided to share what did and didn’t work, and in the end the results were serviceable.

[Bithead] built two hot wire cutters with nichrome wire. The first was small, but the second was larger and incorporated some design refinements. He also got an important safety reminder when he first powered on with his power supply turned up too high; the wire instantly turned red and snapped with an audible bang. He belatedly realized he was foolishly wearing neither gloves nor eye protection.

When it came to use his self-made tools, one of the biggest discoveries was that not all foam is equal in the eyes of a hot wire cutter. This is one of those things that’s common knowledge to experienced people, but isn’t necessarily obvious to a newcomer. A hot wire cutter that made clean and effortless cuts in styrofoam did no such thing with the foam he was using to cast his droid’s outer shell. Still, he powered through it and got serviceable results. [Bithead]’s blog post may not have anything new to people who have worked with foam and hot wire cutters before, but if you’re new to such things you can use it to learn from his experiences. And speaking of improving experiences, [Bithead] most recently snazzed up the presentation of his R2-D2 build by getting tricky with how he hides his remote control.

Hackaday Prize Entry: Arduino Splash Resistant Toilet Foamer

There are some universal human experiences we don’t talk about much, at least not in public. One of them you’ll have in your own house, and such is our reluctance to talk about it, we’ve surrounded it in a fog of euphemisms and slang words. Your toilet, lavatory, john, dunny, khazi, bog, or whatever you call it, is part of your everyday life.

For his Hackaday Prize entry, [VijeMiller] tackles his smallest room head-on. You see, for him, the chief horror of the experience lies with the dreaded splashback. Yes, a bit of projectile power dumping leaves the old rump a little on the damp side. So he’s tackled the problem with some maker ingenuity and installed an Arduino-controlled foam generator that injects a mixture of soap and glycerin to fill the bowl with a splash-damping load of foam. Rearward inundation avoided.

The parts list reveals that the foam is generated by a fish tank aerator, triggered by a relay which is driven by an Arduino Uno through a power transistor. A solenoid valve controls the flow, and a lot of vinyl tubing hooks it all together. There is an HC/06 Bluetooth module with an app to control the device from a phone, though while he’s posted some Arduino code there is no link to the app. There are several pictures, including a cheeky placement of a Jolly Wrencher, and a shot of what we can only surmise is a text, as foam overflows all over the bathroom. And he’s put up the video we’ve placed below the break, for a humorous demonstration of the device in action.

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Metal Casting With Single Shelled PLA Masters

[3DTOPO] does a lot of metal casting (video link, embedded below). That’s obvious by the full and appropriate set of safety gear, a rarity on YouTube.

They had all the equipment to do it the normal way: craft or CNC out a master, produce a drag and a copy, make any necessary cores, and finally; pour the mold. This is a long and tedious process. It has a high rate of error, and there is a parting line.

Another set of methods are the lost ones. With these methods the master is produced out of a material like foam or wax. The master is surrounded by refractory and then melted, burned, or baked out of the mold. Finally the metal is poured in. Theoretically, a perfect reproduction is made without ever having to open the mold.
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Resurrecting a 1960’s VTR with Foam

Nearly fifty years back, Sony launched the DVC-2400, their first consumer grade video camera. This unit weighed in at 10 pounds, and recorded only 20 minutes of footage per reel. It left something to be desired for $1250, or nearly $9000 in today’s dollars.

[NeXT] got his hands on one of these camera kits, and began bringing it back to life. While all the pieces were included, the Video Tape Recorder (VTR), which is used to play back the footage, didn’t power up. A little poking found a dead transistor. After determining a modern replacement part, the voltages checked out. However, the drum still wasn’t spinning.

Further disassembly found that the drum’s DC motor was made on the cheap, using a foam instead of springs to apply pressure on the brushes. This foam had worn out and lost its springy qualities, so no electrical contact was made. New foam was cut out as a replacement. Once reassembled, the drum spun successfully. After some adjustment, the VTR was running at the correct speed once again.

With this working, the VTR should be ready to go. However, camera still isn’t working, so we’re awaiting a part 2.