3D Printed Circular Prototype Performance Prop Captivates Circus Spectators

February 2, 2022 by Ryan Flowers 12 Comments

When mathematically inspired maker [Henry Segerman] conspired with circus performer and acrobat [Marcus Paoletti] to advance the craft of acrobatics in round metal objects (such as cyr wheels and German Wheels), they came up with a fascinating concept that has taken shape in what [Henry] calls the Tao-Line.

Similar performance devices go in a straight line or can be turned on edge, but the Tao-Line is far more nimble. This is because the Tao-Line is not a continuous cylinder, but rather is made up of numerous circular shapes that allow the Tao-Line to be turned and inverted at different points in its rotation.

While a circus prop might not be your average Hackaday fare, it’s noteworthy because the Tao-Line started off as a 3D printed prototype, which was then turned into the metal fabrication you see in the video below the break. It’s an excellent example of how modeling complex shapes as a physical product- not just a 3D model on the screen- can be helpful in the overall design and construction of the full scale piece.

If you’re looking to build something that’s under the big top but not quite so over the top, you might enjoy this mixed-media digital clock. Thanks to [Keith] for the great tip. Be sure to submit send your cool finds via the Tip Line!

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USB Power Has Never Been Easier

January 5, 2022 by Brian McEvoy 48 Comments

USB cables inevitably fail and sometimes one end is reincarnated to power our solderless breadboards. Of course, if the cable broke once, it is waiting to crap out again. Too many have flimsy conductors that cannot withstand any torque and buckle when you push them into a socket. [PROSCH] has a superior answer that only takes a couple of minutes to print and up-cycles a pair of wires with DuPont connectors. The metal tips become the leads and the plastic sheathing aligns with the rim.

The model prints with a clear plus sign on the positive terminal, so you don’t have to worry about sending the wrong polarity, and it shouldn’t be difficult to add your own features, like a hoop for pulling it out, or an indicator LED and resistor. We’d like to see one with a tiny fuse holder.

If you want your breadboard to have old-school features, like a base and embedded power supply, we can point you in the right direction. If you are looking to up your prototyping game to make presentation-worthy pieces, we have a host of ideas.

Keynote Video: Jeremy Fielding Wants To Help You Get Moving

December 23, 2021 by Tom Nardi 7 Comments

For many DIY hardware projects, the most movement it’s likely to see is when we pick the assembled unit up off the workbench and carry it to wherever it’s destined to spend the rest of its functional life. From weather sensors to smart mirrors, there’s a huge array of devices that don’t need to move one millimeter to function. But eventually, you’re likely to run into a project that’s a bit more dynamic. Maybe you’d like to motorize your window shades, or go all out and build a remote controlled rover. With these more active designs comes a whole slew of new problems you may never have encountered before.

Luckily for us, folks like Jeremy Fielding are out there and willing to share their knowledge. In his fascinating presentation for the 2021 Hackaday Remoticon, Building Hardware that Moves: the Fundamentals that Everyone Should Know, he took viewers on a whirlwind tour of what he’s learned about designing and building complex machines from his years of professional experience. Whether its a relatively simple articulated workbench for the shop, a gargantuan earthmoving machine, or a high-dexterity robotic arm, each project he’s worked on has presented unique challenges that needed to be solved.

Not all of Jeremy’s machines will fit in your average workshop.

A lot of the projects that Jeremy has worked on are on a much larger scale than what your average hobbyist is ever going to run into. When there’s an arrow pointing out the tiny human in a picture of you and the machine you’re currently working on, you know things are getting serious. But as anyone who’s watched his YouTube videos knows, he’s got a real knack for taking these high-level concepts and distilling them into something more digestible for the home gamer.

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Ordering prototypes like they were fast food

Made To Spec: The Coming Age Of Prototyping As A Service

December 8, 2021 by Sonya Vasquez 38 Comments

In the last decade, the price for making a single PCB plummeted. And we’ve featured tons of hacks with boards hailing from places like OSH Park or Seeed Studio. But this phenomenon isn’t isolated, and all sorts of one-off prototyping services are becoming cheaper and looking to satiate both hobbyist and engineer alike.

Today, I want to blow the lid off a few places offering one-off mechanical prototyping services. I’ll take us through some history of how we got here, introduce a few new players, and finally highlight some important tradeoffs before you start ordering bespoke aluminum parts straight to your doorstep.

Now go get your ANSI Z87+ safety glasses, and let’s get started.

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Keep Scraps Around

August 21, 2021 by Elliot Williams 30 Comments

When I’m building something, I like to have a decent-sized scrap pile on hand. Because when I’ve got to test something out — does this glue adhere to this fabric, how much force will this hold if I tap it and put a screw in, will it snap if reinforced with carbon fiber and epoxy — it’s nice to have some of the material in question on hand just for experimentation. So I pull a chunk out of the scrap pile!

But scrap piles can’t expand forever, and we all know that “too much of a good thing” is a thing, right? Scrap piles require constant pruning. You don’t really need more than a few aluminum extrusion cutoffs, so when you start building up excess inventory, it’s time to scrap it. I mean, throw it away.

A corollary of this, that I’ve only recently started to appreciate, is that if I limit the number of materials that I’m working with, it’s a lot more manageable to keep the scrap pile(s) under control. It’s simple math. If I’m working with twenty different materials, that’s twenty different heaps of scrap. But if I can get by with one weight of fiberglass for everything, that one pile of scraps can do double or triple duty. There is also the added benefit that I already know how the material works, and maybe even have old test samples on hand.

Indeed, I’m such a scrapaholic that it’s almost painful to start working with a new material and not have a scrap pile built up yet. I’m always loathe to cut into a nice square piece of stock just to test something out. But this too is part of the Great Circle of Life. By not testing things out beforehand, I’m almost guaranteed to screw up and create scrap out of what I had hoped was going to be a finished piece. See? No problem! Next version.

What do you think? Are scrap, offcuts, and their close cousins — test pieces and samples — worth keeping around in your shop? Do you have a disciplined approach, or do you just throw them in the corner? Purge per project, or only when the mountain of XPS foam gets as high as your head?

3D-Printed, Hot-Swap Keyboard PCB Generator Is Super Cool

July 12, 2021 by Kristina Panos 4 Comments

About a month ago, [50an6xy06r6n] shared their hot swap 3D-printed circuit board for keyboard design with the mechanical keyboard subreddit. It’s more of a prototyping tool than a permanent fixture, though nothing is stopping you from using it permanently. Well, now it’s even better, and open source to boot.

[50an6xy06r6n] came up with this to test split ergo layouts faster and not have to solder anything — the switch pins make contact with the row wires and folded diode legs. In fact, prepping all the diodes is probably the thing that takes the longest.

The design can be generated from layout data, or you can convert directly from a KLE JSON file. We love how delightfully clean this keyboard breadboard generator looks, and we wish we had thought of it!

[50an6xy06r6n]’s PCB generator currently supports Cherry MX/clones and Kailh Choc switch footprints. If you want ALPS, somebody’s gonna have to send [50an6xy06r6n] some ALPS to make that happen.

As long as all the contact points are good, you should be able to use this as the final PCB indefinitely. We’ve certainly seen our share of 3D-printed wire guides. Really, you could print the whole thing, including the switches.

Flexible Prototyping For E-Textiles That Doesn’t Cost An Arm And A Leg

June 22, 2021 by Kristina Panos 3 Comments

Let’s face it: pretty much everything about e-textiles is fiddly. If wearables were easy, more people would probably work in that space. But whereas most circuit prototyping is done in two dimensions, the prototyping of wearables requires thinking and planning in 3D. On top of that, you have to figure out how much conductive thread you need, and that stuff’s not cheap.

[alch_emist] has a method for arranging circuits in 3D space that addresses the harsh realities of trying to prototype wearables. There’s that whole gravity thing to deal with, and then of course there are no straight lines anywhere on the human body. So here’s how it works: [alch_emist] made a bunch of reusable tie points designed to work with an adhesive substrate such as felt. They laser-cut a set of acrylic squares and drilled a hole in each one to accommodate a neodymium magnet. On the back of each square is a small piece of the hook side of hook-and-loop tape, which makes the tie points stay put on the felt, but rearrange easily.

We love the idea of prototyping with felt because it’s such a cheap and versatile fabric, and because you can easily wrap it around your arm or leg and see how the circuit will move when you do.

Not quite to this planning stage of your next wearable project? Magnets and conductive thread play just as well together in 2D.