Hackaday Superconference: Estefannie’s Daft Punk Helmet

There’s no single formula for success, but if we’ve learned anything over the years of covering cons, contests, and hackathons, it’s that, just like in geology, pressure can create diamonds. Give yourself an impossible deadline with high stakes, and chances are good that something interesting will result. That’s what Estefannie from the YouTube channel “Estefannie Explains It All” did when Bay Area Maker Faire was rolling around last year, and she stopped by the 2018 Hackaday Superconference to talk about the interactive Daft Punk helmet that came out of it.

It’s a rapid-fire tour of Estefannie’s remarkably polished replica of the helmet worn by Guy-Manuel de Homem-Christo, one half of the French electronic music duo Daft Punk. Her quick talk, video of which is below, gives an overview of its features, but we miss the interesting backstory. For that, the second video serves as a kickoff to a whirlwind month of hacking that literally started from nothing.

You’ll Learn it Along the Way

Before deciding to make the helmet, Estefannie had zero experience in the usual tools of the trade. With only 28 days to complete everything, she had to: convert her living room into a workshop; learn how to 3D print; print 58 separate helmet parts, including a mold for thermoforming the visor; teach herself how to thermoform after building the tools to do so; assemble and finish all the parts; and finally, install the electronics that are the hallmark of Daft Punk’s headgear.

The three videos in her series are worth watching to see what she put herself through. Estefannie’s learning curve was considerable, and there were times when nothing seemed to work. The thermoforming was particularly troublesome — first too much heat, then not enough, then not enough vacuum (pretty common hurdles from other thermoforming projects we’ve seen). But the finished visor was nearly perfect, even if it took two attempts to tint.

We have to say that at first, some of her wounds seemed self-inflicted, especially seeing the amount of work she put into the helmet’s finish. But she wanted it to be perfect, and the extra care in filling, sanding, priming, and painting the printed parts really paid off in the end. It was down to the wire when BAMF rolled around, with last minute assembly left to the morning of the Faire in the hotel room, but that always seems to be the way with these kinds of projects.

In the end, the helmet came out great, and we’re glad the run-up to the Superconference wasn’t nearly as stressful for Estefannie — or so we assume. And now that she has all these great new skills and tools, we’re looking forward to her next build.

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H2gO Keeps Us from Drying Out

The scientific community cannot always agree on how much water a person needs in a day, and since we are not Fremen, we should give it more thought than we do. For many people, remembering to take a sip now and then is all we need and the H2gO is built to remind [Angeliki Beyko] when to reach for the water bottle. A kitchen timer would probably get the job done, but we can assure you, that is not how we do things around here.

A cast silicone droplet lights up to show how much water you have drunk and pressing the center of the device means you have taken a drink. Under the hood, you find a twelve-node NeoPixel ring, a twelve millimeter momentary switch, and an Arduino Pro Mini holding it all together. A GitHub repo is linked in the article where you can find Arduino code, the droplet model, and links to all the parts. I do not think we will need a device to remind us when to use the bathroom after all this water.

Another intrepid hacker seeks to measure a person’s intake while another measures output.

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Using Lasagna to Make Cost-Saving Molds

Building a one-off prototype is usually pretty straightforward. Find some perfboard and start soldering, weld up some scrap metal, or break out the 3D printer. But if you’re going to do a production run of a product then things need to have a little more polish. In [Eric Strebel]’s case this means saving on weight and material by converting a solid molded part into something that is hollow, with the help of some lasagna.

What [Eric] walks us through in this video is how to build a weep mold. First, the solid part is cast in silicone. Using the cast, some “sheet clay” is applied to the inside which will eventually form the void for the new part’s walls. The clay needs to be flush with the top of the mold, though, and a trick to accomplish this task is to freeze the mold (next to the lasagna) which allows the clay to be scraped without deforming.

From there, the second half of the mold is poured in, using special channels that allow the resin to “weep” out of the mold (hence the name). This two-part process creates a much more efficient part with thin walls, rather than the expensive solid prototype part.

[Eric] is no stranger around these parts, either. He’s an industrial designer with many tips and tricks of the profession, including a method for building a machining tool out of a drill press and a vise as well as some tips for how to get the most out of a low-volume production run of a product you might be producing.

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Hackers vs. Mold: Building a Humidistat Fan

Having a mold problem in your home is terrible, especially if you have an allergy to it. It can be toxic, aggravate asthma, and damage your possessions. But let’s be honest, before you even get to those listed issues, having mold where you live feels disgusting.

You can clean it with the regular use of unpleasant chemicals like bleach, although only with limited effectiveness. So I was not particularly happy to discover mold growing on the kitchen wall, and decided to do science at it. Happily, I managed to fix my mold problems with a little bit of hacker ingenuity.

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DIY Injection Mold Design for the Home Shop

3D printing is great for prototyping, and not bad for limited runs of parts. Unfortunately though it really doesn’t scale well beyond a few pieces, so when you’re ready for the mass market you will need to think about injection molding your parts. But something like that has to be farmed out, right? Maybe not, if you know a thing or two about designing your own injection molds.

The video below comes from [Dave Hakkens] by way of his Precious Plastic project, whose mission it is to put the means of plastic recycling into the hands of individuals, rather than relying on municipal programs.  We’ve covered their work before, and it looks like they’ve come quite a way to realizing that dream. This tutorial by [Dave]’s colleague [Jerry] covers the basic elements of injection mold design, starting with 3D modeling in Solidworks. [Jerry] points out the limitations of a DIY injection molding effort, including how the thickness of parts relates to injection pressure. Also important are features like gentle curves to reduce machining effort, leaving proper draft angles on sprues, and designing the part to ease release from the mold. [Jerry] and [Dave] farmed out the machining of this mold, but there’s no reason a fairly complex mold couldn’t be produced by the home gamer.

When you’re done learning about mold design, you’ll be itching to build your own injection mold machine. Precious Plastic’s tutorial looks dead simple, but this machine looks a little more capable. And why CNC your molds when you can just 3D print them?

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Making a Gun Without a 3D Printer

Around four years ago the world was up in arms over the first gun to be 3D printed. The hype was largely due to the fact that most people don’t understand how easy it is to build a gun without a 3D printer. To that end, you don’t even need access to metal stock, as [FarmCraft101] shows us with this gun made out of melted aluminum cans.

The build starts off by melting over 200 cans down into metal ingots, and then constructing a mold for the gun’s lower. This is the part that is legally regulated (at least in the US), and all other parts of a gun can be purchased without any special considerations. Once the aluminum is poured into the mold, the rough receiver heads over to the machine shop for finishing.

This build is fascinating, both from a machinist’s and blacksmith’s point-of-view and also as a reality check for how easy it is to build a firearm from scratch provided the correct tools are available. Of course, we don’t need to worry about the world being taken over by hoards of angry machinists wielding unlicensed firearms. There’s a lot of time and effort that goes into these builds and even then they won’t all be of the highest quality. Even the first 3D printed guns only fired a handful of times before becoming unusable, so it seems like any homemade firearm, regardless of manufacturing method, has substantial drawbacks.

Thanks to [Rey] for the tip!

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A Great Way to Make Quick and Easy Knobs

Here’s a great way to quickly and easily make attractive and functional knobs with no tools required. All you need is some casting resin (epoxy would do in a pinch), a silicone mold intended for candy, and some socket head bolts. With the right preparation and a bit of careful placement and attention, smooth and functional knob ends are only minutes away. Embedded below is a short video demonstrating the process.

These may not replace purpose-made knobs for final products, but for prototypes or to use around the shop on jigs, clamps, or furniture they certainly fit the bill. With a layer of adhesive fabric or rubber, they might even make serviceable adjustable feet for low-stress loads.

This technique could be extended to reproducing broken or missing dakaware or bakelite knobs. This, of course, would require an original, unbroken knob and a small silicone mold, but it’s still a project that’s well within the capabilities of the garage-bound hacker.

While we’re on the subject of knobs, don’t forget we’ve seen an excellent method of repairing knobs as well.

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