Wi-Fi Sensor For Rapid Prototyping

February 19, 2023 by Bryan Cockfield 4 Comments

There might seem like a wide gulf between the rapid prototyping of a project and learning a completely new electronics platform, but with the right set of tools, these two tasks can go hand-in-hand. That was at least the goal with this particular build, which seeks to use a no-soldering method of assembling electronics projects and keeping code to a minimum, while still maintaining a platform that is useful for a wide variety of projects.

As a demonstration, this specific project is a simple Wi-Fi connected temperature monitoring station. Based around an ESP32 and using a DS18B20 digital temperature sensor, the components all attach to a back plate installed in a waterproof enclosure and are wired together with screw-type terminal breakout boards to avoid the need for soldering. The software suite is similarly easy to set up, revolving around the use of Tasmota and ESPHome, which means no direct programming — although there will need to be some configuration of these tools.

With the included small display, this build makes a very capable, simple, and quick temperature monitor. But this isn’t so much a build about monitoring temperature but about building and prototyping quickly without the need for specialized tools and programming. There is something to be said for having access to a suite of rapid prototyping tools for projects as well, though.

Ply Your Craft With Tubular Origami

December 1, 2022 by Abe Connelly 3 Comments

Researchers at the University of Pennsylvania have just published a paper on creating modular tubular origami machines which they call “Kinegami”, a portmanteau of “kinematic” and “origami”.

The idea behind their work is to create individual modules and joint mechanisms that can then be chained together to create a larger “serial” robot. Some example joints they propose are “prismatic” joints, allowing for linear motion, and “revolute” joints, which allow for rotational motion. One of the more exciting aspects of this process is that the joint mechanisms are origami-like structures which can be constructed from a single piece of flat material which is folded and glued together to make the module. Of particular interest is that the crease pattern for the origami-like folds can be laser cut into a material, cardboard or thin acrylic for example, which can be used as a guide to create the resulting structure. The crease patterns for the supporting structures, such as tubes or joints, can be taken from pre-formatted patterns or customized, so this method is very accessible to the hobbyist and could allow for a rich new method of rapid project prototyping.

The researchers go on to discuss how to create the composition of modules from a specification of joints and links (from a “Denavit-Hartenberg” specification) to attaching the junctures together while respecting curvature constraints (via the “Dubins path”). Their paper offers the gritty details along with the available accompanying source files. Origami hacking is a favorite subject of ours and we’ve featured articles on the use of origami in medical technology to creating inflatable actuators.

Video after the break!

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Dream Projects Face Reality

August 20, 2022 by Elliot Williams 26 Comments

Do you ever get a project stuck in your mind? An idea so good you just keep thinking about it? Going over iterations and options and pros and cons in the back of your mind, or maybe on paper, but having not yet subjected it to the hard work of pulling it into reality? I’ve had one of those lurking around for the last couple weeks, and it’s time for me to get building.

And I’ve got to get started soon, because it’s rare that any project makes the leap from thought to reality unscathed, and when I hold on to the in-thought project too long, I become far too fond of some of the details and nuances that just might not make the cut, or might get in the way of getting a first pass finished. When I really like a (theoretical) solution to a (theoretical) problem, I’ll try to make it work a lot longer than I should, and I can tell I’m getting attached to this one now.

The only cure to this illness is to get prototyping. When the rubber hits the road, and the bolts are tightened, either the solution is a good one or it’s not, and no amount of dreaming is going to change that. Building is a great antidote to the siren song of a dream project. Although it feels now like I don’t want the fantasy to have to adapt to reality, as it inevitably will, I know that getting something working feels a lot better. And it frees me up to start dreaming on the next project… To the workshop!

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 39 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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