A metal spaceship throttle replica with a spherical knob

Razor Crest Control Lever For The Grogu In Your Life

April 2, 2022 by Chris Wilkinson 9 Comments

If you’re looking to add a little more sci-fi authenticity to your gaming setup, you could do much worse than this functional control lever replica that [ZapWizard] has entered into the Hackaday.io Sci-Fi Contest.

Taking inspiration from Disney’s The Mandalorian, this functional prop is almost identical to the throttle seen on the bridge of the Razor Crest gunship, piloted by the television show’s eponymous bounty hunter. The electronic heart of this build is relatively straightforward – a Trinket M0 measures the resistance of an ultra-thin potentiometer, and masquerades as a typical one-axis USB throttle.

The mechanical components and aesthetically pleasing housing is where this project really shines. Helical 3D printed gears smooth out the movement of the solid aluminum throttle shaft, and a simple detent mechanism ‘catches’ the throttle at the middle point. The ballast and baseplate are cut from stainless steel, giving the throttle considerable heft, aiding in its stability on a tabletop (it’s also possible to secure it down using screws or powerful magnets). The throttle case is 3D printed and covered in aluminum foil tape, which is then chemically blackened and aged for that well-loved appearance.

Of course, the most iconic part of this build is the spherical knob, which screws onto the aluminum shaft for Grogu’s convenience. [ZapWizard] put in an order for one over at Custom 3D Stuff, and it absolutely ties the entire build together.

Interested in prop builds from the world of science-fiction, functional or otherwise? Then take a look through the entries in our Sci-Fi Contest. Or better yet, start building your own entry — there’s still about a month to go before the deadline.

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Print-in-Place Connectors Aim To Make Wiring Easier

February 15, 2021 by Dan Maloney 115 Comments

One thing some of us here in the United States have always been jealous of is the WAGO connectors that seem so common in electrical wiring everywhere else in the world. We often wonder why the electrical trades here haven’t adopted them more widely — after all, they’re faster to use than traditional wire nuts, and time is money on the job site.

Wago 221 compact lever connector via the Wago YouTube channel

This print-in-place electrical connector is inspired by the WAGO connectors, specifically their Lever Nut series. We’ll be clear right up front that [Tomáš “Harvie” Mudruňka’s] connector is more of an homage to the commercially available units, and should not be used for critical applications. Plus, as a 3D-printed part, it would be hard to compete with something optimized to be manufactured in the millions. But the idea is pretty slick. The print-in-place part has a vaguely heart-shaped cage with a lever arm trapped inside it.

After printing and freeing the lever arm, a small piece of 1.3-mm (16 AWG) solid copper wire is inserted into a groove. The wire acts as a busbar against which the lever arm squeezes conductors. The lever cams into a groove on the opposite wall of the cage, making a strong physical and electrical connection. The video below shows the connectors being built and tested.

We love the combination of print-in-place, compliant mechanisms, and composite construction on display here. It reminds us a bit of these printable SMD tape tamers, or this print-in-place engine benchmark.

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Hands-Free Oreo Dispenser, Now With Milk

February 9, 2020 by Bryan Cockfield 15 Comments

A while back, [Emiel] aka [The Practical Engineer] created a hands-free Oreo dispenser for his shop. This was a necessary addition to his fleet of handy tools, and allowed him to multitask much more effectively by using a sander, for example, at the same time that he needed to eat a cookie. Of course, this time-saving device was missing one crucial element: milk. [Emiel] is back in this video to show off his milk-dispensing upgrade to his original Oreo dispenser.

A few ideas were considered before [Emiel] decided to build a separate unit for the milk dispenser, so as not to create a gigantic mess any time an Oreo was delivered, and also to maintain some decorum in the shop. He rebuilt the Oreo dispenser with a 3D printer and then also 3D printed the milk dispenser. The chin-activated switch inside the device turns on a small pump which squirts milk into the user’s mouth, presumably after an Oreo has been delivered.

There are a few problems with the build, but most are easily solved by replacing non-food-grade parts with plastic that is more safe for being around consumables. The only other thing we can see here is that it might be a little hard to keep things clean, both inside and out, but most Oreo-related builds like this one have at least some problem with cleanliness that isn’t impossible to keep up with.

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Scratch-Built Ornithopter: Here’s How I Flapped My Way To Flight

May 11, 2018 by Steven Dufresne 35 Comments

One of humankind’s dreams has always been to fly like a bird. For a hacker, an achievable step along the path to that dream is to make an ornithopter — a machine which flies by flapping its wings. An RC controlled one would be wonderful, controlled flight is what everyone wants. Building a flying machine from scratch is a big enough challenge, and a better jumping-off point is to make a rubber band driven one first.

I experimented with designs which are available on the internet, to learn as much as possible, but I started from scratch in terms of material selection and dimensions. You learn a lot about flight through trial and error, and I’m happy to report that in the end I achieved a great little flyer built with a hobby knife and my own two hands. Since then I’ve been looking back on what made that project work, and it’s turned into a great article for Hackaday. Let’s dig in!

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Mechanisms: The Lever, It’s Everywhere

April 26, 2018 by Steven Dufresne 28 Comments

Levers are literally all around us. You body uses them to move, pick up a pen to sign your name and you’ll use mechanical advantage to make that ballpoint roll, and that can of soda doesn’t open without a cleverly designed lever.

I got onto this topic quite by accident. I was making an ornithopter and it was having trouble lifting its wings. For the uninitiated, ornithopters are machines which fly by flapping their wings. The problem was that the lever arm was too short. To be honest, as I worked I wasn’t even thinking in terms of levers, and only realized that there was one after I’d fine-tuned its length by trial and error. After that, the presence of a lever was embarrassingly obvious.

I can probably be excused for not seeing a lever right away because it wasn’t the type we most often experience. There are different classes of levers and it’s safe to say that most people aren’t even aware of this. Let’s take a closer look at these super useful, and sometimes hidden mechanisms known as levers.

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Cat Plays The Silver Ball For Treats

February 8, 2018 by Kristina Panos 12 Comments

It’s pretty easy to train a dog to do things for treats. They’re eager to please. But a cat? Most cats have better things to do than learn tricks no matter how many treats are involved. But if you make an autonomous game out of learning a trick, they just might go for it.

That’s the idea behind Touchy Fishy, a pinball machine for cats. It’s the newest iteration of treat-dispensing machines that [Kim] made for his cat, MIDI. The previous version was shaped like a dog’s head with a joystick for a nose. MIDI was so adept at pulling the joystick toward herself that [Kim] decided to try a new design using a lever.

Humans like challenges, too, and [Kim] wanted to make something purely mechanical this time around. The final product is mostly springs and laser-cut acrylic. MIDI pulls the spring-loaded lever downward, launching a pinball upward in an arc. At the top of its trajectory is a spinner enclosed in a circle. When the pinball hits the spinner, it sweeps a treat toward an opening, and the treat falls down where MIDI can eat it. The best part? The spinner also returns the captive pinball to its starting point, so MIDI can play until [Kim] gets tired of dropping treats into the hole. Watch MIDI claw her way to the high score after the break.

Most of the cat-related projects we’ve seen were built to keep hungry cats from sitting on their owner’s chests at 3AM, demanding to be fed. Here’s one that goes a step further by putting the cat to work collecting wiffle balls which it uses to pay for small amounts of kibble.

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Repairs You Can Print: Racing The Clock For A Dishwasher Fix

January 31, 2018 by Dan Maloney 38 Comments

No matter how mad your 3D printing skills may be, there comes a time when it makes more sense to order a replacement part than print it. For [billchurch], that time was the five-hour window he had to order an OEM part online and have it delivered within two days. The race was on — would he be able to model and print a replacement latch for his dishwasher’s detergent dispenser, or would suffer the ignominy of having to plunk down $30 for a tiny but complicated part?

As you can probably guess, [bill] managed to beat the clock. But getting there wasn’t easy, at least judging by the full write-up on his blog. The culprit responsible for the detergent problem was a small plastic lever whose pivot had worn out. Using a caliper for accurate measurements, [bill] was able to create a model in Fusion 360 in just about two hours. There was no time to fuss with fillets and chamfers; this was a rush job, after all. Still, even adding in the 20 minutes print time in PETG, there was plenty of time to spare. The new part was a tight fit but it seemed to work well on the bench, and a test load of dishes proved a success. Will it last? Maybe not. But when you can print one again in 20 minutes, does it really matter?

Have you got an epic repair that was made possible by 3D printing? We want to know about it. And if you enter it into our Repairs You Can Print Contest, you can actually win some cool prizes to boot. We’ve got multiple categories and not that many entries yet, so your chances are good.