3D Printed Forklift Is A Cute Desk Toy

December 22, 2024 by Lewin Day 9 Comments

Many of us grew up with dreams of piloting a forklift one day. Sadly, most warehouses take a dim view of horseplay with these machines, so few of us get to live out those fantasies. Playing with this desk-sized RC model from [ProfessorBoots] is probably a safer way to get those kicks instead. You can check it out in the video below.

The 3D-printed body of the forklift is the first thing you see. It’s great quality, and it instantly puts you in mind of the real thing. The build is true to the dynamics of a real forklift, too, with proper rear steering. Inside, there’s a custom circuit board hosting an ESP32 that serves as the brain of the operation. Its onboard wireless hardware allows remote control of the forklift via a smartphone app, PS4 controller, or many other options. It controls the drive motors and steering servo, along with another motor driving a threaded rod to move the forks up and down. The whole thing is powered by two Fenix 16340 batteries—small lithium-ion cells that can be recharged with an integral micro USB port.

The project video is very thorough about the design and build. It’s worth watching just to understand the specifics of how forklifts actually raise their forks up and down. It’s good stuff.

This forklift is just the latest RC build from [ProfessorBoots]. He’s done great work in this space before, like this charming skid steer and incredibly complex crane.

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3D Printed Tires, By The Numbers

October 24, 2024 by Dan Maloney 21 Comments

What does it take to make decent tires for your projects? According to this 3D printed tire torture test, it’s actually pretty easy — it’s more a question of how well they work when you’re done.

For the test, [Excessive Overkill] made four different sets of shoes for his RC test vehicle. First up was a plain PLA wheel with a knobby tread, followed by an exact copy printed in ABS which he intended to coat with Flex Seal — yes, that Flex Seal. The idea here was to see how well the spray-on rubber compound would improve the performance of the wheel; ABS was used in the hopes that the Flex Seal solvents would partially dissolve the plastic and form a better bond. The next test subjects were a PLA wheel with a separately printed TPU tire, and a urethane tire molded directly to a PLA rim. That last one required a pretty complicated five-piece mold and some specialized urethane resin, but the results looked fantastic.

Non-destructive tests on the tires included an assessment of static friction by measuring the torque needed to start the tire rolling against a rough surface, plus a dynamic friction test using the same setup but measuring torque against increasing motor speed. [Overkill] threw in a destructive test, too, with the test specimens grinding against a concrete block at a constant speed to see how long the tire lasted. Finally, there was a road test, with a full set of each tire mounted to an RC car and subjected to timed laps along a course with mixed surfaces.

Results were mixed, and we won’t spoil the surprise, but suffice it to say that molding your own tires might not be worth the effort, and that Flex Seal is as disappointing as any other infomercial product. We’ve seen other printed tires before, but hats off to [Excessive Overkill] for diving into the data.

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RC Car Gets Force Feedback Steering

August 6, 2024 by Bryan Cockfield 8 Comments

Remote-controlled cars can get incredibly fast and complex (and expensive) the farther into the hobby you get. So much so that a lot of things that are missing from the experience of driving a real car start to make a meaningful impact. [Indeterminate Design] has a few cars like this which are so fast that it becomes difficult to react to their behavior fast enough through sight alone. To help solve this problem and bridge the gap between the experience of driving a real car and an RC one, he’s added force feedback steering to the car’s remote control.

The first thing to tackle is the data throughput required to get a system like this working wirelessly. Relying heavily on the two cores in each of a pair of ESP32s, along with a long-range, high-speed wireless communications protocol called ESP-NOW, enough data from the car can be sent to make this possible but it does rely on precise timing to avoid jitter in the steering wheel. Some filtering is required as well, but with the small size of everything in this build it’s also a challenge not to filter out all of the important high-frequency forces. With the code written, [Indeterminate Design] turned to the 3D printer to build the prototype controller with built-in motors to provide the haptic feedback.

The other half of the project involves sensing the forces in the RC car which will then get sent back to the remote. After experimenting with a mathematical model to avoid having to source expensive parts and finding himself at a deadend with that method, eventually a bi-directional load cell was placed inside the steering mechanism which solved this problem. With all of these pieces working together, [Indeterminate Design] has a working force feedback steering mechanism which allows him to feel bumps, understeer, and other sensations, especially while doing things like drifting or driving through grass, that would be otherwise unavailable to drivers of RC cars. The only thing we could think of to bring this even more into realistic simulation territory would be to add something like a first-person view like high-speed drones often have.

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Watch This RC Jet Thrust System Dance

July 19, 2024 by Donald Papp 8 Comments

An EDF (electric duct fan) is a motor that basically functions as a jet engine for RC aircraft. They’re built for speed, but to improve maneuverability (and because it’s super cool) [johnbecker31] designed a 3D-printable method of adjusting the EDF’s thrust on demand.

Before 3D printers were common, making something like this would have been much more work.

The folks at Flite Test released a video in which they built [john]’s design into a squat tester jet that adjusts thrust in sync with the aircraft’s control surfaces, as you can see in the header image above. Speaking of control surfaces, you may notice that test aircraft lacks a rudder. That function is taken over by changing the EDF’s thrust, although it still has ailerons that move in sync with the thrust system.

EDF-powered aircraft weren’t really feasible in the RC scene until modern brushless electric motors combined with the power density of lithium-ion cells changed all that. And with electronics driving so much, and technology like 3D printers making one-off hardware accessible to all, the RC scene continues to be fertile ground for all sorts of fascinating experimentation. Whether it’s slapping an afterburner on an EDF or putting an actual micro jet engine on an RC car.

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RC Batwing Actually Flies

June 16, 2024 by Bryan Cockfield 8 Comments

Batman is a compelling superhero for enough reasons that he’s been a cultural force for the better part of a century. His story has complex characters, interesting explorations of morality, iconic villains, and of course a human superhero who gets his powers from ingenuity instead of a fantastical magical force. There are a number features of the Batman universe that don’t translate well to the real world, though, such as a costume that would likely be a hindrance in fights, technology that violates the laws of physics, and a billionaire that cares about regular people, but surprisingly enough his legendary Batwing jet airplane actually seems like it might be able to fly.

While this is admittedly a model plane, it flies surprisingly well for its nontraditional shape. [hotlapkyle] crafted it using mostly 3D printed parts, and although it took a few tries to get it working to his standards, now shoots through the air quite well. It uses an internal electric ducted fan (EDF) to get a high amount of thrust, and has elevons for control. There are two small vertical stabilizer fins which not only complete the look, but allow the Batwing to take to the skies without the need for a flight controller.

Not only is the build process documented in the video linked below with some interesting tips about building RC aircraft in general, but the STL files for this specific build are available for anyone wanting to duplicate the build or expand on it. There are plenty of other interesting 3D-printed models on [hotlapkyle]’s page as well that push the envelope of model aircraft. For some other niche RC aircraft designs we’ve seen in the past be sure to check out this F-35 model that can hover or this tilt-rotor Osprey proof-of-concept.

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DIY RC Controller Built With Old-School Parts

March 20, 2024 by Lewin Day 16 Comments

Once upon a time, RC transmitters were expensive units that cost hundreds of dollars even at the low end. Now, you can get them pretty cheaply, or, you can choose to build your own. [Phytion] did just that.

The design isn’t based around a modern microcontroller, nor does it rely on WiFi or Bluetooth connections. Instead, it’s a little more old school. It’s built using the HT12E parallel-to-serial encoder chip, and the HT12D decoder chip for the receiver. The controller uses a pair of HT12Es on the transmitter, and a pair of HT12Ds on the receiver. These accept inputs from a pair of analog joysticks and encode them as serial data. However, they essentially just act as digital joysticks in this design. The HT12Es feed into an STX882 module which transmits the data from the HT12Es over 433 MHz. Another STX882 module receives this signal, and passes it through HT12Ds for decoding.

At the receiving end, one joystick can turn four outputs on or off depending on whether it is pushed up, down, left or right. A channel select switch then allows it to do the same for four further outputs. The second joystick just mirrors the operation of the first. It’s just intended to make controlling something like an RC car easier by allowing one stick to be pushed forwards and backwards, and the other left and right.

You don’t see many designs like this anymore. Realistically, it’s possible to get far more functionality out of a design based on an ESP32 or similar wireless-capable chip. However, this one doesn’t require any complicated handshaking and powers up instantly, which is a nice bonus. Plus, it’s always interesting to see alternative designs tried out in the wild. Video after the break.

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Fail Of The Week: The Little Remote-Controlled Snowblower That Couldn’t

March 3, 2024 by Dan Maloney 17 Comments

[Punxatawny Phil]’s prognostications aside, winter isn’t over up here in the Northern Hemisphere, and the snow keeps falling. If you’re sick of shoveling the driveway and the walk and you don’t have a kid handy to rope into the job, relax — this rapidly assembled junkyard RC snowblower will do just as crappy a job while you stay nice and warm inside.

This build seemed to have a lot of potential at the start, based as it was on a second-hand track-drive snowblower, something that was presumably purpose-built for the job at hand. [Lucas] quickly got to work on it; he left the original gasoline engine to power the auger but took most of the transmission off so that each track could be driven separately with a wheelchair motor. That seemed like a solid idea as far as steering goes, but the fact that he chose to drive the 24 volt motors with a single 12 volt deep-cycle battery worked against him out in the snow.

With a battery upgrade for better traction, the snowblower actually got around in the snow pretty well. [Lucas] also added some nice features, like a linear actuator to remotely engage the auger — a nice safety touch when kids and pets are around — and a motor to control the direction of the chute. Even these improvements weren’t enough, though; it worked insofar as it moved snow from where it was to where it wasn’t, but didn’t really move it very far. To the casual observer, it seems like there’s just not enough weight to the machine, allowing it to ride up over the snow rather than scraping the driveway clean. Check out the video below and see what you think.

Now, we’re not picking on [Lucas] here. Far from it — we enjoyed this build as much as some of his other stuff, like his scratch-built CO2 laser tube and his potty-mouthed approach to Kaizen tool organization. We still think this one has a lot of potential, and we’re glad he vowed to continue working on it for next winter.

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