Behold The Crimson Axlef*cker (Do Not Insert Finger)

Are your aluminum extrusions too straight? The Crimson Axlef*cker can help you out. It’s a remarkable 3D printed, 4-stage, 125:1 reduction gearbox driven by a brushless motor. Designer [jlittle988] decided to test an early prototype to destruction and while he was expecting something to break, he didn’t expect it to twist the 2020 aluminum extrusion shaft before it did. We suppose the name kind of stuck after that.

Internals of the first prototype, shaft of BLDC motor just visible at top. Twisted 2020 extrusion output shaft at bottom right.

[jlittle988] has been documenting the build progress on reddit, and recently posted a fascinating video (embedded below) of the revised gearbox twisting the output shaft even further. He’s a bit coy about the big picture, saying only that the unit is part of a larger project. In fact, despite the showy tests, his goal is not to simply obtain maximum torque. We can only speculate on what his bigger project is, but in the meantime, seeing the gearbox results is some good clean fun. He first announced the gearbox test results here, and swiftly followed it up with some revisions, then the aforementioned video. There’s also an image gallery of the internals, so check that out.

The Crimson Axlef*cker is driven by an ODrive brushless dual-shaft motor and an ODrive controller as well; that’s the same ODrive whose open source motor controller design impressed us so much in the past.

Between projects like this one and other gearboxes like this cycloidal drive, it’s clear that custom gearbox design is yet another door that 3D printing has thrown wide open, allowing hobbyists to push developments that wouldn’t have been feasible even just a few years earlier.

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2019 Hackaday Prize Hack Chat

Join us Wednesday, April 17 at noon Pacific time for the 2019 Hackaday Prize Hack Chat!

The 2019 Hackaday Prize was just announced, and this year the theme is designing for manufacturing. The hacker community has come a long, long way in the last few years in terms of the quality of projects we turn out. Things that were unthinkable just a few short years ago are now reduced to practice, and our benches and breadboards are always stuffed with the latest and greatest components and modules, all teaming up to do wondrous things. But what about the next step? Do you have what it takes to turn that mess o’ wires into a product? What skills do you need to add to your repertoire to make sure you can actually capitalize on your prototype — or more importantly, to get your ideas into someone else’s hands where they can actually do some good? That’s what the Hackaday Prize is all about this year, and we want you taking your projects to the next level!

Majenta Strongheart will be hosting the Hack Chat as we discuss:

  • The importance of designing for manufacturing;
  • What tools we have available to turn prototypes into projects;
  • How the Hackaday Prize is set up this year, and why the theme was selected; and
  • Why you should participate in the 2019 Hackaday Prize

You are, of course, encouraged to add your own questions to the discussion. You can do that by leaving a comment on the 2019 Hackaday Prize Hack Chat and we’ll put that in the queue for the Hack Chat discussion.

join-hack-chatOur Hack Chats are live community events on the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, April 17, at noon, Pacific time. If time zones have got you down, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.

Nixie Power Supply Shows Ins And Out Of Offshore Manufacturing

[Tony] built a high-efficiency power supply for Nixie tube projects. But that’s not what this post is about, really.

As you read through [Tony]’s extremely detailed post on Hackaday.io, you’ll be reading through an object lesson in electronic design that covers the entire process, from the initial concept – a really nice, reliable 170 V power supply for Nixie tubes – right through to getting the board manufactured and setting up a Tindie store to sell them.

[Tony] saw the need for a solid, well-made high-voltage supply, so it delved into data sheets and found a design that would work – as he points out, no need to reinvent the wheel. He built and tested a prototype, made a few tweaks, then took PCBWay up on their offer to stuff 10 boards for a mere $88. There were some gotchas to work around, but he got enough units to test before deciding to ramp up to production.

Things got interesting there; ordering full reels of parts like flyback transformers turned out to be really important and not that easy, and the ongoing trade war between China and the US resulted in unexpected cost increases. But FedEx snafus notwithstanding, the process of getting a 200-unit production run built and shipped seemed remarkably easy. [Tony] even details his pricing and marketing strategy for the boards, which are available on Tindie and eBay.

We learned a ton from this project, not least being how hard it is for the little guy to make a buck in this space. And still, [Tony]’s excellent documentation makes the process seem approachable enough to be attractive, if only we had a decent idea for a widget.

The Primordial Sinclair ZX Spectrum Emerges From The Cupboard

The Centre for Computing History in Cambridge, UK, receive many donations from which they can enrich their collection and museum displays. Many are interesting but mundane, but the subject of their latest video is far from that. The wire-wrapped prototype board they reveal with a flourish from beneath a folded antistatic mat is no ordinary computer, because it is the prototype Sinclair ZX Spectrum.

It came to the museum from Nine Tiles, a local consultancy firm that had been contracted by Sinclair Research in the early 1980s to produce the BASIC ROM that would run on the replacement for their popular ZX81 home microcomputer. The write-up and the video we’ve placed below the break give some detail on the history of the ROM project, the pressures from Sinclair’s legendary cost-cutting, and the decision to ship with an unfinished ROM version meaning that later peripherals had to carry shadow ROMs with updated routines.

The board itself is a standard wire-wrap protoboard with all the major Spectrum components there in some form.  This is a 16k model, there is no expansion connector, and the layout is back-to-front to that of the final machine. The ULA chip is a pre-production item in a ceramic package, and the keyboard is attached through a D connector. Decent quality key switches make a stark contrast to the rubber keys and membrane that Spectrum owners would later mash to pieces playing Daley Thompson’s Decathlon.

This machine is a remarkable artifact, and we should all be indebted to Nine Tiles for ensuring that it is preserved for those with an interest in computing to study and enjoy. It may not look like much, but that protoboard had a hand in launching a huge number of people’s careers in technology, and we suspect that some of those people will be Hackaday readers. We’ll certainly be dropping in to see it next time we’re in Cambridge.

If you haven’t been to the Centre for Computing History yet, we suggest you take a look at our review from a couple of years ago. And if prototype home computers are your thing, this certainly isn’t the first to grace these pages.

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Test PCBs On A Bed Of Nails

While it might be tempting to start soldering a circuit together once the design looks good on paper, experience tells us that it’s still good to test it out on a breadboard first to make sure everything works properly. That might be where the process ends for one-off projects, but for large production runs you’re going to need to test all the PCBs after they’re built, too. While you would use a breadboard for prototyping, the platform you’re going to need for quality control is called a “bed of nails“.

This project comes to us by way of [Thom] who has been doing a large production run of circuits meant to drive nixie tubes. After the each board is completed, they are laid on top of a number of pins arranged to mate to various points on the PCB. Without needing to use alligator clamps or anything else labor-intensive to test, this simple jig with all the test points built-in means that each board can be laid on the bed and tested to ensure it works properly. The test bed looks like a bed of nails as well, hence the name.

There are other ways of testing PCBs after production, too, but if your board doesn’t involve any type of processing they might be hard to implement. Nixie tubes are mostly in the “analog” realm so this test setup works well for [Thom]’s needs.

Mini Vectrex Prototype Restored By National Videogame Museum

The crash of the videogame market in 1983 struck down a slew of victims, and unique products such as the Vectrex were not immune to its destructive ways. The all-in-one console featured a monochromatic vector display and offered an arcade-like experience at home complete with an analog joystick controller. It sadly never made it to its second birthday before being axed in early 1984, however, thanks to the [National Videogame Museum] we now how a glimpse of an alternate history for the Vectrex. They posted some photos of an unreleased Vectrex prototype that was restored to working order.

Little was known about this “Mini version” of the Vectrex as its very existence was called into question. The console came into and left the videogame market in such short order that its distributor, Milton Bradley, would have killed any additional model posthaste. Little thought was given to the idea, though a rumor appeared in Edge magazine issue 122. The article detailed a fan’s memory of seeing a Vectrex shaped “like a shoebox” on the president’s desk.

Seven years after the publication of that story, photos of the Vectrex design revision were posted by one of the Vectrex designer’s sons on Flickr. These photos served as the only concrete evidence as to the existence of the machine that were widely available for some time. That was until the [National Videogame Museum] managed to acquire the actual prototype as part of the museum’s collection in Frisco, TX. So for those without plans to swing through the DFW area in the near future, there is the video of the mini Vectrex in action below.

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With Grinning Keyboard And Sleek Design, This Synth Shows It All

Stylish! is a wearable music synthesizer that combines slick design with stylus based operation to yield a giant trucker-style belt buckle that can pump out electronic tunes. With a PCB keyboard and LED-surrounded inset speaker that resembles an eyeball over a wide grin, Stylish! certainly has a unique look to it. Other synthesizer designs may have more functions, but certainly not more style.

The unit’s stylus and PCB key interface resemble a Stylophone, but [Tim Trzepacz] has added many sound synthesis features as well as a smooth design and LED feedback, all tied together with battery power and integrated speaker and headphone outputs. It may have been originally conceived as a belt buckle, but Stylish! certainly could give conference badge designs a run for their money.

The photo shown is a render, but a prototype is underway using a milled PCB and 3D printed case. [Tim]’s Google photo gallery has some good in-progress pictures showing the prototyping process along with some testing, and his GitHub repository holds all the design files, should anyone want a closer look under the hood. Stylish! was one of the twenty finalists selected for the Musical Instrument Challenge portion of the 2018 Hackaday Prize and is therefore one of the many projects in the running for the grand prize!