Product teardowns are great, but getting an unfiltered one from the people who actually designed and built the product is a rare treat. In the lengthy video after the break, former Formlabs engineer [Shane Wighton] tears down the Form 4 SLA printer while [Alec Rudd], the engineering lead for the project, answers all his prying questions.
[Shane] was part of the team that brought all Form 4’s predecessors to life, so he’s intimately familiar with the challenges of developing such a complex product. This means he can spot the small design details that most people would miss, and dive into the story behind each one. These include the hinges and poka-yoke (error-proofing) designed into the lid, the leveling features in the build-plate mount, the complex prototyping challenges behind the LCD panel and backlight, and the mounting features incorporated into every component.
A considerable portion of the engineering effort went into mitigating all the ways things could go wrong in production, shipping, and operation. The fact that most of the parts on the Form 4 are user-replaceable makes this even harder. It’s apparent that both engineers speak from a deep well of hard-earned experience, and it’s well worth the watch if you dream of bringing a physical product to market.
LEGOs are the first window into making something in your head become real for many makers. The Verge dug into how a LEGO set itself goes from idea to the shelves.
While most sets come from the minds of LEGO designers, since 2008, fans can submit their own sets to LEGO Ideas for the chance to become a real product. In this case, we follow the journey of [Marc Corfmat]’s Polaroid OneStep Camera from his initial attempts at LEGO stardom with his brother [Nick] to the current set that took off.
While the initial idea and build are the seed for a new set, once the project is in the hands of LEGO, designers meticulously make revision after revision to ensure the set is enjoyable to build and any moving parts continue to function for thousands of cycles. This is all weighed against the total cost of the BOM as well as any licensing required for intellectual property. One particularly interesting part of the article is how designers at LEGO are afforded a certain number of “frames” for custom bricks which leads to some interesting hacks and collaboration as all good constraints do.
[Michael Lynch] has been a solo developer for over three years now, and has been carefully cataloguing his attempts at generating revenue for himself ever since making the jump to being self-employed. Success is not just hard work; it is partly knowing when the pull the plug on an idea, and [Micheal] has been very open about his adventures in this area. He shares the good news about a DIY project of his that ended up becoming a successful product, complete with dollar amounts and frank observations.
About a year ago, we covered a project he shared called TinyPilot, which is an effective KVM-over-IP device, accessible over the web, that could be built with about $100 worth of parts. [Micheal] found it to be a fun and useful project, and decided to see if he could sell kits. However, he admits he didn’t have high expectations, and his thoughts are probably pretty familiar to most hardware types:
I questioned whether there was a market for this. Why would anyone buy this device from me? It was just a collection of widely available hardware components.
Well, it turns out that he was onto something, and the demand for his device became immediately clear. He’s since given TinyPilot more features, an attractive case, and even provides a support plan for commercial customers. This is an excellent reminder that sometimes, what is being sold isn’t the collection of parts itself. Sometimes, what’s being sold is a solution to a problem people have, and those people are time-poor and willing to pay for something that just works.
It’s great to see [Michael] find some success as a solo developer, but his yearly wrap-up covers much more than just the success of TinyPilot as a product, so be sure to check it out if you’re at all interested in the journey of working for yourself.
There aren’t many brands that inspire the kind of passion and fervency among its customers as Tektronix does. The venerable Oregon-based manufacturer of top-end test equipment has produced more collectible gear over the last 75 years than just about anyone else.
Over that time they have had plenty of innovations, and in the 1970s they started looking into miniaturizing their flagship oscilloscopes. The vintageTEK museum, run by current and former employees, has a review of the design process of the 200 series of portable oscilloscopes that’s really interesting. At a time when scopes were portable in the way a packed suitcase is portable, making a useful instrument in a pocketable form factor was quite a challenge — even for big pockets.
The article goes into great detail on the back-and-forth between the industrial designers, with their endless stream of models, and the engineers who would actually have to stuff a working scope into whatever case they came up with. The models from the museum’s collection are wonderful bits of history and show where the industrial designers really pushed for some innovative designs.
Some of the models are clearly derived from the design of the big bench scopes, but some have innovative flip-down covers and other interesting elements that never made it to production. Most of the models are cardboard, but some were made of aluminum in the machine shop and sport the familiar “Tek blue” livery. But the pièce de résistance of the collection is a working engineering model of what would become the 200-series of miniscopes, a handmade prototype with a tiny round CRT and crudely labeled controls.
The vintageTEK museum sounds like another bucket-list stop for computer and technology history buffs. Tek has been doing things their own way for a long time, and stopping by the museum is sure to be a treat.
Breakout board for the MAX30101, which [Zach] used as the basis of his roast gauge. The sensor is at the top edge of the board.Parts designed and marketed for a specific application can nevertheless still be useful in other ways, and whenever that happens, it’s probably the start of a pretty good hack. Using a sensor for something other than its intended purpose is exactly what [Zach Halvorson] did to make the Roast Vision device, which uses the MAX30101, a sealed optical sensor intended mainly for pulse oximetry and heart-rate monitoring.
[Zach] is instead using that sensor to measure the roast level of coffee beans, and assign a consistent number from 0 to 35 to represent everything from Very Dark to Very Light. Measuring a bean’s roast level is important to any roaster seeking accuracy and consistency, but when [Zach] found that commercial roast gauges could easily cost over a thousand dollars, he was sure he could do better.
[Zach] settled on using a Sparkfun MAX30101 breakout board to develop his device, and Sparkfun shared an informative blog post that demonstrates how making hardware and tools more accessible can help innovative ideas flourish. The Roast Vision device has a 3D printed enclosure, and a simple top-loading design with an integrated sample cup makes it easy to use. One simply puts about a teaspoon of finely-ground coffee into the sample cup, and the unit provides a measurement in a couple of seconds. Fortunately the sensor works just fine though an acrylic window which means the device can be sealed; a handy feature for a tool that will spend a lot of time around ground coffee.
Beau Ambur can often be found hosting hardware events and offering help all around the Bay Area. Now he’s turned it into a career and travels the west coast helping hackers and creators effectively leverage Kickstarter’s platform. Beau’s mentor session covers everything from, “is this project a good fit for venture capital?” to, “is open source a good fit for my project?”.
For this year’s Hackaday Prize we’ve found experts in a wide range of fields so you can take your entries to the next level regardless of the stage the project is in. The sessions are on a first come basis so sign up now for a chance to get some valuable feedback on your entry.
Your Robot Language Coach
The first project is a Personal English Trainer by the lonely programmer. As a student he noticed a need for a more interactive and portable language learning aid. Solutions do exist on the market but they are along the lines of a pocket dictionary, instructional phone app, or a full on translator. These break the flow of thought and conversation. The lonely programmer envisioned something that you can conversationally ask for help as you’re using a new language.
As many have discovered, the best way to see if there’s a need for something is to build a minimum viable product (MVP). The snips.ai platform offered the perfect foundation to quickly test out the idea. It’s working on a few words and he wants to get it ready for more people to play with the idea. The majority of the lonely programmer’s questions centered around making the project interesting for other hackers so that it could one day turn into a product.
Bolt-On Bike Assist
Rob and Shushanik are developing a project called BikeOn. It bolts to any bicycle and converts it to an electric assist bike without tools or replacing any components. BikeOn has already won some accolades such as Editors Choice at the last 2019 Makerfaire Bay Area. Rob had a few questions on how to transition a project from the proof of concept stage to the product stage. The discussion went over using open source as a tool for product promotion as well as getting funding for taking a hardware product to market.
He also wanted to know if there was anything the team could do to have a better shot at winning the prize. There were a few good tips such as directly focusing on the five categories the judges would be looking at: Concept, Design, Production, Benchmark, and Communication. It is also important to cover the development journey. Why did you make the choices you made when designing the project?
No-Spill Trash Can Concept
Rounding out this mentor session, Jeannie and her team of highschool students demonstrate SEAL. In the area around the Granada Hills Charter High School there are winds mighty enough to blow over full trashcans. This trash travels to the ocean and disrupts local ecosystems. The team is working on a device which can detect a tipping trashcan and keep the lid from opening.
Prototyping started with Arduinos, but they’ve already escalated to designing their own PCBs. Their hope is to produce a run of fifty devices and try them out with a local commercial partner. Beau recommended they look into the Micropython ecosystem. Not only would the students get the advantage of using the STM32 chips in their board layouts (reducing the number of support components they would need), micropython would make it easier for students to jump in and help rather than having to learn the nuances of C first.
The Hackaday Prize mentoring sessions continue through the summer so don’t forget to sign up and check out the list of mentors who are here to share their knowledge and experience.
For whatever you have built, there is someone who has done it longer, and knows more about it. That is the basic premise of expertise, and for this year’s Hackaday Prize we’re rolling out with a series of mentor sessions. These are master classes that match up experts in product development with the people behind the projects in the Hackaday Prize. We’ve been recording all of these so everyone can benefit from the advice, guidance, and mentorship presented in these fantastic recordings.
The DrumKid, a random drum synthesizer
Mitch Altman is someone who should be very familiar to all Hackaday readers. He’s the inventor of the TV-B-Gone, that wonderful device that simultaneously turns you into a hero and a villain in any sports bar. He’s the President and CEO of Cornfield Electronics and co-founder of the Noisebridge hackerspace in San Francisco. Mitch is an author and teacher, and seems to be at just about every conference and workshop around the world promoting hackerspaces, Open Source hardware, and mentorship where ever he goes.
The first hardware creator to meet Mitch is Matt Bradshaw, creator of the DrumKid. This is a pocket-sized drum machine that is heavily inspired by Teenage Engineering’s Pocket Operators. Years ago, Matt built a web app that generated drum tracks, and this project is simply taking that idea into the physical realm. For Mitch, this is well-tread territory; years ago, Mitch also built an Arduino-based synth, and for the most part, both Mitch and Matt’s projects are remarkably similar. There were, however, some improvements to be made with Matt’s circuit. The power supply was two AAA batteries and a switching regulator that introduced noise and added cost. Mitch suggested that the ATMega328 could be run directly from three AA batteries reducing the cost and the noise.
eAgrar, a system for monitoring conditions of plants and weather conditions at agricultural fields
The next project up for review is eAgrar, a system for monitoring conditions of plants and the weather in fields. This project comes from Slaven Damjanovic and Marko Čalić. They’ve been developing this device for almost two years building the entire system around the ATMega328. Slaven ran into a problem with this chip in that he didn’t have enough inputs and outputs. The firmware is already written, but thanks to the Arduino IDE, there’s no reason to keep using that ATMega. Mitch suggested using an STM32 or another ARM core. That’s what he’s using for one of his synthesizer projects, and you get more than enough inputs and outputs for the same price as an ATMega.
Finally, we come to Joseph, with his project, the Pilates Reformer. A Pilates Reformer is a bit of exercise equipment that’s only made by three companies and everything costs thousands of dollars. Joseph is bringing that cost down, but there’s a problem: how do you build a hundred or two hundred of these? Mitch suggested simply finding another manufacturer that could build this design, and not necessarily one that builds Pilates machines. This makes sense — if all you’re doing is cutting and connecting structural beams, any manufacturer can do this, that’s what manufacturers do.
This is the third in our series of Hackaday Prize mentor sessions this year, and we have far more we need to edit, and many more we need to record. That doesn’t mean you can’t get help from experts from your prize entry; we’re looking for people who need help with their project and we have a lot of mentors willing to dispense advice. If you’re interested in having someone look over your shoulder, sign up your entry.
Rounding out this mentor session, Jeannie and her team of highschool students demonstrate 
