Designing A Pen Clip That Never Bends Out Of Shape

March 3, 2026 by Lewin Day 7 Comments

If you’ve ever used a ballpoint pen with a clip on the top, you’ve probably noticed they bend pretty easily. The clip relies on you only bending it a small amount to clip it on to things; bend it too far, and it ends up permanently deformed. [Craighill] decided to develop a pen clip that didn’t suffer this ugly malady.

The wire clip design easily opens wide because the spring wire is not actually deforming much at all. Credit: YouTube video, via screenshot

The problem with regular pen clips comes down to simple materials science. Bend the steel clip a little bit, and the stress in the material remains below the elastic limit—so it springs back to its original shape. Push it too far, though, and you’ll end up getting into the plastic deformation region, where you’ve applied so much stress that the material is permanently deformed.

[Craighill] noted this problem, and contemplated whether a better type of clip was possible. An exploration of carabiner clips served to highlight possible solutions. Some carabiners using elastically-deformed closures that faced the same problem, while others used more complicated spring closures or a nifty bent-wire design. This latter solution seemed perfect for building a non-deforming pen clip. The bent wire is effectively a small spring, which allows it to act as a clip to hold the pen on to something. However, it’s also able to freely rotate out from the pen body, limiting the amount of actual stress put on the material itself, which stops it entering the plastic deformation region that would ruin it.

It’s some neat materials science combined with a pleasant bit of inventing, which we love to see. Sometimes there is joy to be had in contemplating and improving even the simplest of things. Video after the break.

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Gentle Processing Makes Better Rubber That Cracks Less

August 15, 2025 by Lewin Day 22 Comments

Rubber! It starts out as a goopy material harvested from special trees, and is then processed into a resilient, flexible material used for innumerable important purposes. In the vast majority of applications, rubber is prized for its elasticity, which eventually goes away with repeated stress cycles, exposure to heat, and time. When a rubber part starts to show cracks, it’s generally time to replace it.

Researchers at Harvard have now found a way to potentially increase rubber’s ability to withstand cracking. The paper, published in Nature Sustainability, outlines how the material can be treated to provide far greater durability and toughness.

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A blue-gloved hand holds a glass plate with a small off-white rectangular prism approximately one quarter the area of a fingernail in cross-section.

AI Helps Researchers Discover New Structural Materials

February 27, 2025 by Navarre Bartz 18 Comments

Nanostructured metamaterials have shown a lot of promise in what they can do in the lab, but often have fatal stress concentration factors that limit their applications. Researchers have now found a strong, lightweight nanostructured carbon. [via BGR]

Using a multi-objective Bayesian optimization (MBO) algorithm trained on finite element analysis (FEA) datasets to identify the best candidate nanostructures, the researchers then brought the theoretical material to life with 2 photon polymerization (2PP) photolithography. The resulting “carbon nanolattices achieve the compressive strength of carbon steels (180–360 MPa) with the density of Styrofoam (125–215 kg m⁻³) which exceeds the specific strengths of equivalent low-density materials by over an order of magnitude.”

While you probably shouldn’t start getting investors for your space elevator startup just yet, lighter materials like this are promising for a lot of applications, most notably more conventional aviation where fuel (or energy) prices are a big constraint on operations. As with any lab results, more work is needed until we see this in the real world, but it is nice to know that superalloys and composites aren’t the end of the road for strong and lightweight materials.

We’ve seen AI help identify battery materials already and this seems to be one avenue where generative AI isn’t just about making embarrassing photos or making us less intelligent.

Software Lets You Paint Surface Patterns On 3D Prints

January 25, 2025 by Adam Fabio 19 Comments

Just when you think you’ve learned all the latest 3D printing tricks, [TenTech] shows up with an update to their Fuzzyficator post-processing script. This time, the GPL v3 licensed program has gained early support for “paint-on” textures.

Fuzzyficator works as a plugin to OrcaSlicer, Bambu Studio, and PrusaSlicer. The process starts with an image that acts as a displacement map. Displacement map pixel colors represent how much each point on the print surface will be moved from its original position. Load the displacement map into Fuzzyficator, and you can paint the pattern on the surface right in the slicer.

This is just a proof of concept though, as [TenTech] is quick to point out. There are still some bugs to be worked out. Since the modifications are made to the G-code file rather than the model, the software has a hard time figuring out if the pattern should be pressed into the print, or lifted above the base surface. Rounded surfaces can cause the pattern to deform to fit the surface.

If you’d like to take the process into your own hands, we’ve previously shown how Blender can be used to add textures to your 3D prints.

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Molybdenene whiskers. (Credit: Sahu et al., 2023)

Introducing Molybdenene As Graphene’s New Dirac Matter Companion

November 12, 2023 by Maya Posch 9 Comments

Amidst all the (well-deserved) hype around graphene, it’s important to remember that its properties are not unique to carbon. More atoms can be coaxed into stable 2-dimensional configuration, with molybdenene previously theoretically possible. This is now demonstrated by Tumesh Kumar Sahu and colleagues in a recent Nature Nanotechnology article, through the manufacturing of a 2D molybdenum-based material which they showed to be indeed molybdenene. Essentially, this is a 2D lattice of molybdenum atoms, a configuration in which it qualifies as Dirac matter, just like graphene. For those of us unfamiliar with Dirac materials, this gentle introduction by Jérôme Cayssol in Comptes Rendus Physique might be of use.

Manufacturing process of molybdenene. (Credit: Sahu et al., 2023)

In order to create molybdenene, the researchers started with molybdenum disulfide (MoS₂), which using a microwave-assisted field underwent electrochemical transformation into whiskers that when examined turned out to consist out of monolayers of Mo. The sulfur atoms were separated using a graphene sheet. As is typical, molybdenene sheets were exfoliated using Scotch tape, in a process reminiscent of the early days of graphene research.

Much like graphene and other Dirac materials, molybdenene has many potential uses as a catalyst, as cantilever in scanning electron microscope (SEM) tips, and more. If the past decades of research into graphene has demonstrated anything, it is that what once seemed more of a novelty, suddenly turned out to have endless potential in fields nobody had considered previously. One of these being as coatings for hard disk platters, for example, which has become feasible due to increasingly more efficient ways to produce graphene in large quantities.

Hackaday Prize 2023: Universal Tensile Testing Machine

August 17, 2023 by Lewin Day 4 Comments

Material testing is important in big industry, where manufacturers must be able to trust the properties of the raw materials they’re using. The rest of us generally take a supplier’s word for it that they’re giving us what we’ve paid for. However, you could always take on material testing yourself with the Universal Tensile Testing Machine from [Xieshi Zhang].

Unlike a six-figure industrial machine, this build is much more affordable, costing on the order of $300 to build. It uses an Arduino to read a tensile strain gauge, and is capable of applying up to a kilonewton of force. To achieve this, it uses a NEMA 17 stepper motor driving a lead screw to apply tensile strain or compression to the specimen under test. The test fixture is assembled from 3D-printed components, and built on top of a piece of aluminium extrusion.

Fundamentally, it’s a smaller version of a machine most engineering undergraduates will see in a materials lab experiment. It could be highly useful for anyone wanting to experiment with 3D printed structures; it would be more than capable of testing various filaments and infill types for their tensile and compression performance. Video after the break.

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Hinges Live Inside 3D Prints

May 1, 2023 by Bryan Cockfield 5 Comments

Since desktop 3D printers have become more common, we’ve seen dramatic shifts in all kinds of areas such as rapid prototyping, antique restoration, mass production of consumer goods, or even household repairs that might not have been possible otherwise. There are a lot of unique manufacturing methods that can be explored in depth with a 3D printer as well, and [Slant 3D] demonstrates how one such method known as the living hinge can be created with this revolutionary new tool.

Living hinges, unlike a metal hinge you might pick up at a hardware store, are integrated into the design of the part and made of the same material. Typically found in plastic containers, they allow for flexibility while keeping parts count and cost low. The major downside is that they create stresses in the materials when used, so their lifespan is finite. But there are a number of ways to extend their life, albeit with a few trade-offs.

The first note is to make sure that you’re using the right kind of plastic, but after that’s taken care of [Slant 3D] builds a few flexible parts starting with longer circular-shaped living hinge which allows greater range of motion and distributes the forces across a wider area, at a cost of greater used space and increased complexity. A few other types of living hinges are shown to use less space in some areas, but make the hinges only suitable for use in other narrower applications.

One of the more interesting living hinges he demonstrates is one that’s more commonly seen in woodworking, known there as a kerf bend. By removing strips of material from a sheet, the entire sheet can be rotated around the cuts. In woodworking this is often done by subtracting material with a CNC machine or a laser cutter, but in 3D printing the voids can simply be designed into the part.

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