Powercore Aims To Bring The Power Of EDM To Any 3D Printer

March 7, 2023 by Dan Maloney 39 Comments

The desktop manufacturing revolution has been incredible, unleashing powerful technologies that once were strictly confined to industrial and institutional users. If you doubt that, just look at 3D printing; with a sub-$200 investment, you can start making parts that have never existed before.

Sadly, though, most of this revolution has been geared toward making stuff from one or another type of plastic. Wouldn’t it be great if you could quickly whip up an aluminum part as easily and as cheaply as you can print something in PLA? That day might be at hand thanks to Powercore, a Kickstarter project that aims to bring the power of electric discharge machining (EDM) to the home gamer. The principle of EDM is simple — electric arcs can easily erode metal from a workpiece. EDM machines put that fact to work by putting a tool under CNC control and moving a precisely controlled electric arc around a workpiece to machine complex shapes quickly and cleanly.

Compared to traditional subtractive manufacturing, EDM is a very gentle affair. That’s what makes EDM attractive to the home lab; where the typical metal-capable CNC mill requires huge castings to provide the stiffness needed to contain cutting forces, EDM can use light-duty structures and still turn out precision parts. In fact, Powercore is designed to replace the extruder of a bog-standard 3D printer, and consists almost entirely of parts printed on the very same machine. The video below shows a lot of detail on Powercore, including the very interesting approach to keeping costs down by creating power resistors from PCBs.

While we tend to shy away from flogging crowdfunded projects, this one really seems like it might make a difference to desktop manufacturing and be a real boon to the home lab. It’s also worth noting that this project has roots in the Hackaday community, being based as it is on [Dominik Meffert]’s sinker EDM machine.

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Building A Plasma Piano Ain’t Easy

February 8, 2023 by Lewin Day 17 Comments

Electronic arcs can be made to “sing” if you simply modulate them on and off at audible frequencies. We’ve seen it done with single Tesla coils, and even small Tesla choirs, but [Mattias Krantz] took this to extremes by building an entire “plasma piano” using this very technique.

The build relies on ten transformers more typically used in cathode ray tubes. The transformers are capable of generating high enough voltages to create arcs in the air. The transformers are controlled by an Arduino, which modulates the arcs at musical frequencies corresponding to the keys pressed on the piano. Sensing the keys of the piano is achieved with a QRS optical sensor strip designed for performance capture from conventional pianos. For the peak aesthetic, the transformer outputs are connected to the metal hammers of the piano, and the arcs ground out on a metal plate in the back of the piano’s body. This lets arcs fly across the piano’s whole width as its played. Ten transformers are used to enable polyphony, so the piano to play multiple tones at once.

Building the piano was no mean feat for [Mattias], who admitted to having very limited experience with electronics before beginning the build. However, he persevered and got it working, while thankfully avoiding injury from high voltage in the process. This wasn’t easy, as Arduinos would regularly freeze from the noise produced by the arcs and the system would lose all control. However, with some smart software tweaks to the arc control and some insulating panels, [Mattias] was able to get the piano playable quite well with a beautiful chiptune tone.

It bears stating that HV work can be dangerous, and you shouldn’t try it at home without the proper understanding of how to do so safely. If you’re confident though, we’ve featured some great projects in this space before. Video after the break.

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Hackaday Links: December 11, 2022

December 11, 2022 by Dan Maloney 13 Comments

“They paved paradise and put up a parking lot.” That might be stretching things a bit, especially when the “paradise” in question is in New Jersey, but there’s a move afoot to redevelop the site of the original “Big Bang Antenna” that has some people pretty upset. Known simply as “The Horn Antenna” since it was built by Bell Labs in 1959 atop a hill in Holmdel, New Jersey, the antenna was originally designed to study long-distance microwave communications. But in 1964, Bell Labs researchers Arno Penzias and Robert Wilson accidentally discovered the microwave remnants of the Big Bang, the cosmic background radiation, using the antenna, earning it a place in scientific history. So far, the only action taken by the township committee has been to authorize a study to look into whether the site should be redeveloped. But the fact that the site is one of the highest points in Monmouth County with sweeping views of Manhattan has some people wondering what’s really on tap for the site. A petition to save the antenna currently has about 3,400 signatures, so you might want to check that out — after all, you don’t know what you’ve got ’til it’s gone.

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Tesla Coil Makes Sodium Plasma

November 26, 2022 by Al Williams 11 Comments

Looking for a neat trick to do with your Tesla coil? [The Action Lab] uses his coil to make a metal plasma — in particular, sodium. You can see the results in the video below.

To create a metal plasma, you need a metal vapor and sodium can create a vapor at a relatively low temperature, especially in a vacuum. The resulting glow is pretty to look at, but you will need a bit of lab gear to pull it off.

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Neon Lamps — Not Just For Pilot Lights

September 13, 2022 by Dan Maloney 30 Comments

It’s easy to see why LEDs largely won out over neon bulbs for pilot light applications. But for all the practical utility of LEDs, they’re found largely lacking in at least one regard over their older indicator cousins: charm. Where LEDs are cold and flat, the gentle orange glow of a neon lamp brings a lot to the aesthetics party, especially in retro builds.

But looks aren’t the only thing these tiny glow lamps have going for them, and [David Lovett] shows off some of the surprising alternate uses for neon lamps in his new video. He starts with an exploration of the venerable NE-2 bulb, which has been around forever, detailing some of its interesting electrical properties, like the difference between the voltage needed to start the neon discharge and the voltage needed to maintain it. He also shows off some cool neon lamp tricks, like using them for all sorts of multi-vibrator circuits without anything but a few resistors and capacitors added in. The real fun begins when he breaks out the MTX90 tube, which is essentially a cold cathode thyratron. The addition of a simple control grid makes for some interesting circuits, like single-tube multi-vibrators.

The upshot of all these experiments is pretty clear to anyone who’s been following [David]’s channel, which is chock full of non-conventional uses for vacuum tubes. His efforts to build a “hollow state” computer would be greatly aided by neon lamp circuits such as these — not to mention how cool they’d make everything look.

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Remoticon 2021 // Jay Bowles Dips Into The Plasmaverse

March 3, 2022 by Lewin Day No comments

Every hacker out there is familiar with the zaps and sizzles of the Tesla coil, or the crash and thunder of lighting strikes on our hallowed Earth. These phenomena all involve the physics of plasma, a subject near and dear to Jay Bowles’s heart. Thus, he graced Remoticon 2021 with a enlightening talk taking us on a Dip Into the Plasmaverse.

Jay’s passion for the topic is obvious, having fallen in love with high voltage physics as a teenager. He appreciated how tangible the science was, whether it’s the glow of neon lighting or the heating magic of the common microwave. His talk covers the experiments and science that he’s studied over the past 17 years and in the course of running his Plasma Channel YouTube channel. Continue reading “Remoticon 2021 // Jay Bowles Dips Into The Plasmaverse” →

Exploring The Healing Power Of Cold Plasma

November 12, 2021 by Tom Nardi 22 Comments

It probably won’t come as much surprise to find that a blast of hot plasma can be used to sterilize a surface. Unfortunately, said surface is likely going to look a bit worse for wear afterwards, which limits the usefulness of this particular technique. But as it turns out, it’s possible to generate a so-called “cold” plasma that offers the same cleansing properties in a much friendlier form.

While it might sound like science fiction, prolific experimenter [Jay Bowles] was able to create a reliable source of nonthermal plasma for his latest Plasma Channel video with surprisingly little in the way of equipment. Assuming you’ve already got a device capable of pumping out high-voltage, all you really need to recreate this phenomenon is a tank of helium and some tubing.

Cold plasma stopped bacterial growth in the circled area.

[Jay] takes viewers through a few of the different approaches he tried before finally settling on the winning combination of a glass pipette with a copper wire run down the center. When connected to a party store helium tank and the compact Slayer Exciter coil he built last year, the setup produced a focused jet of plasma that was cool enough to touch.

It’s beautiful to look at, but is a pretty light show all you get for your helium? To see if his device was capable of sterilizing surfaces, he inoculated a set of growth plates with bacteria collected from his hands and exposed them to the cold plasma stream. Compared to the untreated control group the reduction in bacterial growth certainly looks compelling, although the narrow jet does have a very localized effect.

If you’re just looking to keep your hands clean, some soap and warm water are probably a safer bet. But this technology does appear to have some fascinating medical applications, and as [Jay] points out, the European Space Agency has been researching the concept for some time now. Who knows? In the not so distant future, you may see a similar looking gadget at your doctor’s office. It certainly wouldn’t be the first time space-tested tech came down to us Earthlings.

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