Bringing Fiction To Life With 3D Printing

April 2, 2018 by Tom Nardi 27 Comments

I print something nearly every day, and over the last few years, I’ve created hundreds of practical items. Parts to repair my car, specialized tools, scientific instruments, the list goes on and on. It’s very difficult for me to imagine going back to a time where I didn’t have the ability to rapidly create and replicate physical objects at home. I can say with complete honesty that it has been an absolutely life-changing technology for me, personally.

But to everyone else in my life, my friends and family, 3D printers are magical boxes which can produce gadgets, weapons, and characters from their favorite games and movies. Nobody wants to see the parts I made to get my girlfriend’s 1980’s Honda back on the road before she had to go to work in the morning, they want to see the Minecraft block I made for my daughter. I can’t get anyone interested in a device I made to detect the algal density of a sample of water, but they all want me to run off a set of the stones from The Fifth Element for them.

As I recently finished just such a project, a 3D printed limpet mine from Battlefield 1, I thought I would share some thoughts on the best practices for turning fiction into non-fiction.

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Iron Man Mask With A HUD!

March 25, 2018 by James Hobson 12 Comments

At some point, a child will inevitably dream of being a superhero. Not all children get the chance to see that dream made manifest, but a few take that destiny into their own hands. Redditor [Lord_of_Bone] — seizing at that goal — has built himself an Iron Man mask with an integrated HUD!

Relying on a conceptually similar project he’d previously built, much of the code was rehashed for this ‘Mark II’ version. Pieces of a smartphone holo pyramid act as projection surfaces — using a lens to focus the image to be viewed at such close distances — and a pair of OLED screens displaying the information. It’s a happy bonus that the lack of backlight results in only the text showing in the user’s field of view.

Instead of speaking with J.A.R.V.I.S., [Lord_of_Bone] is using a Raspberry Pi Zero W as the mask’s brain. Working past some I2C troubles between the OLED screens and an Enviro pHat required a whipped-up veroboard and a bit of hardware hacking. Cramming everything into the mask was no easy task — using Blutack and Sugru to bind them in the limited space — but the pHat had to be surface-mounted in the open anyways for atmospheric and light data.

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Building A Tricorder Prop Worthy Of Mr Spock

March 19, 2018 by Tom Nardi 24 Comments

We’ve all been there. You want to assemble a proper Star Trek: The Original Series landing party prop set, but the TOS tricorders you can find on the market are little more than overpriced toys. Imagine the embarrassment of beaming down to Cestus III with a plastic tricorder. The Metrons wouldn’t have even bothered with the trial by combat with such a sorry showing.

Unhappy with the state of Star Trek props, [Dean O] decided to take matters into his own hands. He purchased a TOS tricorder from Diamond Select Toys and set out to modify it into something a bit closer to Starfleet standards. Anything painted metallic silver on the toy was replaced with a machined aluminum duplicate, adding some much needed heft. He even spruced up the controls and display.

To start, [Dean] stripped the tricorder down, separating all of the silver plastic parts and finding aluminum stock that was close enough to the desired dimensions. This ended up being .125″ plate for the sides, and .500″ bars for the horizontal dividers. To make the side panels he placed the original plastic parts over the aluminum, marked the mounting holes with a punch, and used the belt sander to shape them.

[Dean] then put in a more screen accurate Moire disc, and went as far as to get real watch crowns for the buttons (just like the prop used in the show). In a particularly bold move, he even drilled out the center of watch crowns to install plastic light pipes for LED illumination.

Last year we saw a build that crammed a Raspberry Pi into the same Diamond Select tricorder toy to excellent effect. Now somebody just needs to combine both projects and they’ll have the slickest tricorder in the Alpha Quadrant.

Skull Cane Proves Bondo Isn’t Just For Dents

February 22, 2018 by Tom Nardi 11 Comments

[Eric Strebel] is quickly becoming a favorite here at Hackaday. He’s got a fantastic knack for turning everyday objects into something awesome, and he’s kind of enough to document his builds for the viewing pleasure of hackers and makers everywhere. It also doesn’t hurt that his voice and narration style gives us a real Bob Ross vibe.

The latest “Happy Accident” out of his workshop is a neat light-up cane made from a ceramic skull found at a local store. But while the finished cane itself might not be terribly exciting, the construction methods demonstrated by [Eric] are well worth the price of admission. Rather than using Bondo like the filler we’re all accustomed to, he shows how it can be used to rapidly build free-form structures and components.

After building up layers of Bondo, he uses a cheese grater to smooth out the rough surface and a hobby knife to clean up the edges. According to [Eric], one of the benefits of working with Bondo like this is that it’s very easy to shape and manipulate before it fully hardens; allowing you to really make things up as you go.

[Eric] also shares a little secret about how he makes his gray Bondo: he mixes some of the toner from a laser printer cartridge into it. This allows you to very cheaply augment the color of the filler, and is definitely something to file away for future reference.

If the video below leaves you hungry for more [Eric Strebel], check out his fantastic series on working with foam core, which should lead you right down the rabbit hole to his DIY foam core spray painting booth.

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Beating Life-Force Amulet

February 4, 2018 by James Hobson 17 Comments

It’s one thing to see science-fiction slowly become reality, but quite another to take that process into your own hands. Inspired by a movie prop, [Eric Strebel] decided to build himself a 21st science-fiction artifact: a pulsing, life-force amulet.

At the — aheam — heart of this amulet is a blinking LED circuit which [Strebel] modified into a slow pulse with the help of his friends. To add to the surreal quality of the amulet, he sourced a stone from a local gem show, bringing his circuit along to get an idea of what the final product would look like. Once [Strebel] had shaped the stone to a more manageable size, he took a polyester filler mold of its rear face to use as a base from which to cast a durable resin housing for the circuit.

[Strebel] is using a pair of coin cell batteries which fit snugly behind the glowing LED, and in case he ever needs to get inside the amulet, he’s attached the stone to the rear with sew-on straps — super-gluing them to each piece. He went for a bit of an industrial look for the necklace — a braided oil line with a modified quick-release clasp that works like a charm.

How does this amulet stack up to one from the 23rd century? You be the judge!

Start Your Apollo Collection With An Open Source DSKY

February 2, 2018 by Dan Maloney 20 Comments

Given that there have been only six manned moon landings, and that almost all of the hardware that started on the launch pad was discarded along the way, getting your hands on flown hardware is not generally the business of mere mortals. Such artifacts are mostly in museums or in the hands of very rich private collectors. Enthusiasts have to settle for replicas like this open source Apollo Guidance Computer DSKY.

The DSKY, or Display and Keyboard, was the user interface for the Apollo Guidance Computer, that marvel of 1960s computer engineering that was purpose-built to control the guidance and navigation of the Command and Lunar Excursion modules. [ST-Geotronics] has made a decent replica of the DSKY using 3D-printed parts for the housing and bezel. There’s a custom PCB inside that houses a matrix of Neopixels for the indicator light panel and seven-segment LEDs for the numeric displays. Sadly but understandably, the original electroluminescent display could not be reproduced, but luckily [Fran Blanche] is working on just that project these days. The three-segment displays for the plus and minus signs in the numeric displays proved impossible to source commercially, so the team had to roll their own for that authentic look. With laser cut and engraved overlays for the displays and keycaps, the look is very realistic, and the software even implements a few AGC-like functions.

We like this a lot, although we could do without the sound clips, inspirational though Kennedy’s speech was. Everything is open source so you can roll your own, or you can buy parts or even a complete kit too.

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Giving Stranger Things For Christmas

January 24, 2018 by James Hobson 5 Comments

[rudolph] was at a loss on what to get his niece for Christmas. It turns out she’s a huge fan of Stranger Things, so the answer was obvious: make her an alphabet wall she can control!

Downsizing the scale to fit inside a document frame, [rudolph] calls their gift rudLights, and a key parameter of this build was to make it able to display any phrases sent from their niece’s Amazon Fire tablet instead of constantly displaying hard-coded phrases. To do so, it has a HC-05 Bluetooth module to forward the commands to the NeoPixel LEDs running on a 5V DC power supply.

[rudolph] enlisted the help of their son to draw up the alphabet display — printed straight onto thematically decorative wallpaper — and cut out holes in the light bulbs for the LEDs. Next up was cut some fibre board as a firm backing to mount the electronics inside the frame and drill holes for the NeoPixels. It was a small odyssey to cut and solder all the wires to the LEDs, but once done, [rudolph] divided their rudLight alphabet into three rows and added capacitors to receive power directly.

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