More LEDs Means Faster Print Times For 3D Printer, But There’s A Catch

November 18, 2020 by Donald Papp 13 Comments

[Jan Mrázek] is no stranger at all to home-grown improvements with his Elegoo Mars SLA 3D printer, and there is a lot going on in his experimental multi-LED upgrade which even involved casting his own lens array. In the end it did speed up his prints by a factor of three to four, though he cooked an LCD to failure in the process. Still, it was a fun project done during a COVID-19 lockdown; as usual there is a lot to learn from [Jan]’s experiences but the mod is not something he necessarily recommends people do for themselves.

[Jan] started by wondering whether better print quality and performance could be obtained by improving the printer’s UV light source. The stock printer uses a single large UV LED nestled into a reflector, but [Jan] decided to try making a more precise source of UV, aiming to make the UV rays as parallel as possible.

To do this, he took a two-pronged approach. One was to replace the single large UV LED with a 4×7 array of emitters plus heat sink and fans. The other was to make a matching array of custom lenses to get the UV rays as parallel as possible.

Casting one’s own lens array out of clear epoxy was a lot of work and had mixed results, but again, it was a lockdown project and the usual “is-this-really-worth-it” rules were relaxed. In short, casting a single custom lens out of clear epoxy worked shockingly well, but when [Jan] scaled it up to casting a whole 4×7 array of them, results were mixed. Mold deformation and artifacts caused by the areas between individual lenses robbed the end result of much of its promise.

More success was had with the array of UV emitters, which enabled faster curing thanks to higher power, but the heat needs to be managed. The stock emitter of the printer is about 30 W, and [Jan] was running his new array at 240 W. This meant a blazing fast one second exposure time per layer, but the heat generated by the new lighting was higher than anticipated. After only ten hours the LCD failed, probably at least in part due to the heat. [Jan] halved the power of the array down to 120 W and added an extra fan, which appears to have done the trick. Exposure time is two to three seconds per layer, and it’s up to 150 hours of printing without problems.

Again, it’s not a process [Jan] necessarily recommends to others (and he definitely recommends buying lenses if at all possible instead of casting them) but as usual there is a lot to learn from his frank sharing of results, both good and bad. We’ve seen 3D-printed lenses as well as adding WiFi connectivity to one of these hobbyist printers, and it’s great to see the spirit of hacking alive and well when it comes to these devices.

“Artificial Sun” Lighting Via Old Satellite Dishes

November 13, 2020 by Lewin Day 53 Comments

Real sunlight is a beautiful thing, but due to the vagaries of Earth’s orbit and local weather systems, it’s not available all the time. [Matt] decided this wasn’t good enough, and set about building a rig to replicate the sun’s rays as closely as possible.

Rayleigh scattering is emulated by passing the light through a glass chamber filled with soapy water – taking advantage of the Tyndall effect.

The great distance between the Sun and the Earth means that the sun’s rays are essentially parallel from our local vantage point. Replicating this, and the soothing nature of a blue sky, were [Matt]’s primary goals with the project. To achieve this, an old satellite dish was pressed into service as a parabolic reflector, coated with mirror-finish vinyl strips. A 500W white LED with a good color rendering index was fitted at the focal point, outfitted with a water cooling system to shed heat. With a point source at its focal point, the parabolic reflector bounces the light such that it the rays are parallel, giving the sense that the light source is coming from an effectivelyl infinite distance away. To then achieve the blue sky effect, the light was then passed through a glass chamber filled with soapy water, which scatters the light using the Tyndall effect. This mimics the Rayleigh scattering in Earth’s atmosphere.

The final result is amazing, with [Matt] shooting footage that appears to be filmed in genuine daylight – despite being shot at night or on rainy days. He also features a cutdown build that can be achieved in a far cheaper and compact form, using Fresnel lenses and blue film. We’ve featured [Matt]’s daylight experiments before, though we’re amazed at the new level reached. Video after the break.

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Visualizing Magnetic Memory With Core 64

November 11, 2020 by Adam Zeloof 17 Comments

For the vast majority of us, computer memory is a somewhat abstract idea. Whether you’re declaring a variable in Python or setting a register in Verilog, the data goes — somewhere — and the rest really isn’t your problem. You may have deliberately chosen the exact address to write to, but its not like you can glance at a stick of RAM and see the data. And you almost certainly can’t rewrite it by hand. (If you can do either of those things, let us know.)

These limitations must have bothered [Andy Geppert], because he set out to bring computer memory into the tangible (or at least, visible) world with his interactive memory badge Core 64. [Andy] has gone through a few different iterations, but essentially Core 64 is an 8×8 grid of woven core memory, which stores each bit via magnetic polarization, with a field of LEDs behind it that allow you to visualize what’s stored. The real beauty of this setup is that it it can be used to display 64 pixel graphics. Better yet — a bit can be rewritten by introducing a magnetic field at the wire junction. In other words, throw a magnet on a stick into the mix and you have yourself a tiny drawing tablet!

This isn’t the first time we’ve seen cool experiments with core memory, and not even the first time we’ve seen [Andy] use it to make something awesome, but it really illuminates how the technology works. Being able to not only see memory being written but to manually write to it makes it all so much realer, somehow.

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Prism Lighting – The Art Of Steering Daylight

November 9, 2020 by Moritz v. Sivers 33 Comments

The incandescent light bulb was one of the first early applications of electricity, and it’s hard to underestimate its importance. But before the electric light, people didn’t live in darkness — they thought of ways to redirect sunlight to brighten up interior spaces. This was made possible through the understanding of the basic principles of optics and the work of skilled glassmakers who constructed prism tiles, deck prisms, and vault lights. These century-old techniques are still being applied today for the diffusion of LEDs or for increasing the brightness of LCD displays.

Semantics First!

People in optics are a bit sloppy when it comes to the definition of a prism. While many of them are certainly not geometric prisms, Wikipedia defines it as a transparent optical element with flat, polished surfaces of which at least one is angled. As can be seen in the pictures below some of the prisms here do not even stick to this definition. Browsing the catalog of your favorite optics supplier you will find a large variety of prisms used to reflect, invert, rotate, disperse, steer, and collimate light. It is important to point out that we are not so much interested in dispersive prisms that split a beam of white light into its spectrum of colors, although they make great album covers. The important property of prisms in this article is their ability to redirect light through refraction and reflection.

A Safe Way to Bring Light Under Deck

A collection of deck lights used to direct sunlight below deck in ships. Credit: glassian.org

One of the most important uses of prism lighting was on board ships. Open flames could have disastrous consequences aboard a wooden ship, so deck prisms were installed as a means to direct sunlight into the areas below decks. One of the first patents for deck lights “THE GREAT AND DURABLE INCREASE OF LIGHT BY EXTRAORDINARY GLASSES AND LAMPS” was filed by Edward Wyndus as early as 1684. Deck prisms had typical sizes of 10 to 15 centimeters. The flat top was installed flush with the deck and the sunlight was refracted and directed downward from the prism point. Because of the reversibility of light paths (“If I can see you, you can see me”) deck prisms also helped to spot fires under deck. Continue reading “Prism Lighting – The Art Of Steering Daylight” →

Dad Scores Big With DIY Indoor Hockey Game

November 7, 2020 by Kristina Panos No comments

We suppose it’s a bit early to call it just yet, but we definitely have a solid contender for Father of the Year. [DIY_Maxwell] made a light-up hockey game for his young son that looks like fun for all ages. Whenever the puck is hit with the accompanying DIY hockey stick (or anything else), it lights up and produces different sounds based on its acceleration.

Inside the printed puck is an Arduino Nano running an MPU6050 accelerometer, a 12-NeoPixel ring, and a piezo buzzer. [DIY_Maxell] reused a power bank charging circuit to charge up the small LiPo battery.

The original circuit used a pair of coin cells, but the Arduino was randomly freezing up, probably because of the LEDs’ current draw. Be sure to check out the video after the break, which begins with a little stop motion and features a solder stand in the shape of a 3D printer.

Got a house full of carpet or breakables? You could always build an air hockey table instead.

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3D Printed Workshop Lamp Uses A Few Neat Tricks

November 4, 2020 by Lewin Day 18 Comments

As far as light fittings go, store bought is fine, but it’s hard to beat something you’ve built yourself from the ground up. [Heliox] demonstrates this well, with a 3D-printed workshop lamp that looks the business and is functional, too.

The lamp has plenty of neat design touches that speak to [Heliox]’s experience in the 3D printed arts. The articulating arms are modular, and feature integrated cable guides. The lamp base features nuts inserted mid-print for easy assembly, and the swivel is actually a two-piece mechanism printed as a single assembly. The table clamp uses a large screw, and the benefit of 3D printing means its easy to customise to suit any individual table. Using black and orange filaments gives the lamp a proper industrial look, and the bright LED strips are perfect for illuminating a bench for fine detailed work.

It’s a great addition to [Heliox]’s workspace, and the tall articulated design means it can cast light without getting in the way of what you’re doing. We’ve featured her work before, too – like this glorious infinity cube. Video after the break.

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Computer Vision Maps Christmas Lights

November 3, 2020 by Bryan Cockfield 27 Comments

There’s a small but dedicated group of folks out there who spend all year planning their Christmas decorations. These aren’t simple lawn ornaments or displays, either, but have evolved into complex lightning performances that require quite a bit of computer control. For some things, hooking up a relay to a microcontroller can get the job done, but [Andy] has turned to computer vision to solve some of the more time-consuming aspects of these displays.

Specifically, [Andy] has a long string of programmable RGB LED lights to wrap around a Christmas tree, but didn’t want to spend time manually mapping out each light’s location. So he used OpenCV to register the locations of the LEDs from three different camera angles, and then used a Python script to calculate their position in the 3D space. This means that he will easily be able to take the LEDs down at the end of the holidays and string them back up next year without having to do the tedious manual mapping ever again.

While [Andy] notes that he may have spent more time writing the software to map out the LEDs than manually doing it himself, but year-after-year it may save him a lot of time and effort, not to mention the benefits of a challenge like writing this software in the first place. If you want to get started on your own display this year, all you really need is some lights and a MIDI controller.