Printed Nexus 7 SIM Tray Is Good ‘Nuff

February 2, 2018 by Tom Nardi 9 Comments

When repairing something, there are in effect two schools of thought: you can craft a repair that seamlessly blends into the original hardware and doesn’t look like a repair, or you can slap that thing together and keep it moving. A lot of variables go into this decision making process, such as the complexity of the repair, the available materials, and of course whether or not you need to keep the fact you broke the thing from your significant other.

When the SIM holder on his Nexus 7 tablet broke recently, [Alex Whittemore] did the mental arithmetic and came to the conclusion that it wasn’t worth his time trying to figure out how to model an exact replacement. But he was able to print something that works well enough for his purposes, which is all that matters in the end. A perfect entry for our ongoing “Repairs You Can Print” contest.

Apparently the SIM holder in the 2013 Nexus 7 is notoriously poor, and of course since this is a known issue, online retailers are trying to get as much as $100 USD out of you for a tiny sliver of plastic. Sometimes it really seems like Google was determined to run the Nexus line into the ground before bailing on it.

Printing such a tiny part, especially with the little details like the channel for you to hook your fingernail into, requires a fairly well calibrated printer. If you can’t muster up a 0.1mm first layer you might as well sit this one out; and if you haven’t mastered the art of bridging, that little valley to help you get the SIM back out may end up overflowing into a river of tears.

For [Alex], the piece ended up working perfectly. It might look a little weird, but if you’ve got the tablet in a case you’ll never see it anyway. It’s also worth noting that this design may work on other devices with a similar SIM arrangement, or at the very least, might be a good starting point to work from if you’ve got to come up with your own.

Remember, there’s still plenty of time to enter your own printed fix into our “Repairs You Can Print” contest. The top 20 repairs will take home $100 in Tindie credit, and for the best repair done by a Student or Organization, there’s two Prusa i3 MK3 printers with the Quad Material upgrade kits on the line.

Repairs You Can Print: Fixing A Chewed Up Remote

February 1, 2018 by Dan Maloney 17 Comments

What is it about remote controls? They’re like some vortex of household chaos, burrowing into couch cushions while accusations fly about who used it last. Or they land in just the right spot on the floor to be stepped on during a trip to the bathroom. And don’t get us started about the fragility of their battery case covers; it’s a rare remote in a house with kids whose batteries aren’t held in by strips of packing tape.

But [Alex Rich]’s Bose radio remote discovered another failure mode: imitating a dog chew toy. Rather than fork out $90 for a replacement, [Alex] undertook a 3D-printed case to repair the chewed remote. He put an impressive amount of reverse engineering into the replacement case, probably expending much more than $90 worth of effort. But it’s the principle of the thing, plus he wanted to support some special modifications to the stock remote. One was a hardware power switch to disconnect the batteries entirely, hidden in the bottom shell of the case. The second was the addition of a link to his thermostat to adjust the volume automatically when the AC comes on. That required a Trinket inside the remote and a few mods to make room for it.

Yes, this project dates from a few years back, but [Alex] only just brought it to our attention for the Repairs You Can Print contest. Got some special unobtanium part that you were able to print to get out of a jam? Enter and win prizes to add to the glory of fixing something yourself.

Repairs You Can Print: Racing The Clock For A Dishwasher Fix

January 31, 2018 by Dan Maloney 38 Comments

No matter how mad your 3D printing skills may be, there comes a time when it makes more sense to order a replacement part than print it. For [billchurch], that time was the five-hour window he had to order an OEM part online and have it delivered within two days. The race was on — would he be able to model and print a replacement latch for his dishwasher’s detergent dispenser, or would suffer the ignominy of having to plunk down $30 for a tiny but complicated part?

As you can probably guess, [bill] managed to beat the clock. But getting there wasn’t easy, at least judging by the full write-up on his blog. The culprit responsible for the detergent problem was a small plastic lever whose pivot had worn out. Using a caliper for accurate measurements, [bill] was able to create a model in Fusion 360 in just about two hours. There was no time to fuss with fillets and chamfers; this was a rush job, after all. Still, even adding in the 20 minutes print time in PETG, there was plenty of time to spare. The new part was a tight fit but it seemed to work well on the bench, and a test load of dishes proved a success. Will it last? Maybe not. But when you can print one again in 20 minutes, does it really matter?

Have you got an epic repair that was made possible by 3D printing? We want to know about it. And if you enter it into our Repairs You Can Print Contest, you can actually win some cool prizes to boot. We’ve got multiple categories and not that many entries yet, so your chances are good.

Repairs You Can Print: The Zipper Box

January 31, 2018 by Kristina Panos 10 Comments

Picture it: winter, a few years ago. [Ted Yapo]’s son is sent to the front lines of a snowball war. He rises to the task, pelting kid after kid with ease and taking down the Johnson twins with a two-fisted trebuchet maneuver. As he hunkers down to form the last snowball needed to claim victory, the unthinkable happens: the zipper box on his coat breaks and falls silently into the snow. Unaware, he leaps to his feet to take his final shot and the whole zipper unfurls, exposing him to both the cold and the enemy. They won the war, but at what cost?

[Ted] figured the coat was done for. He thought about replacing the zipper entirely, but that was going to be a lot of work. He cast a forlorn look around his workshop and his gaze fell upon the 3D printer in the corner. I can rebuild it! He thought. I have the technology! He was off to design a new box in OpenSCAD and had sturdy ABS replacement zipper box in no time. He installed it with dab of Duco cement, and the rest is history. That coat saw two more winters and countless snowball wars before [Private Yapo] presumably grew out of the thing.

Zippers are the unsung heroes of clothing. If you don’t know much about zippers, sink your teeth into [Dan Maloney]’s recent ode to the quickest fastener we’ve got.

Repairs You Can Print: Broken Glue Gun Triggers Replacement

January 30, 2018 by Kristina Panos 10 Comments

Picture this: you need to buy a simple tool like a glue gun. There’s usually not a whole lot going on in that particular piece of technology, so you base your decision on the power rating and whether it looks like it will last. And it does last, at least for a few years—just long enough to grow attached to it and get upset when it breaks. Sound familiar?

[pixelk] bought a glue gun a few years ago for its power rating and its claims of strength. Lo and behold, the trigger mechanism has proven to be weak around the screws. The part that pushes the glue stick into the hot end snapped in two.

It didn’t take much to create a replacement. [pixelk] got most of the measurements with calipers and then got to work in OpenSCAD. After printing a few iterations, it fit well enough, but [pixelk] saw a chance to improve on the original design and added a few teeth where the part touches the glue stick. The new part has been going strong for three months.

We think this entry into our Repairs You Can Print contest is a perfect example of the everyday utility of 3D printers. Small reproducible plastic parts are all around us, just waiting to fail. The ability to not only replace them but to improve on them is one of the brightest sides of our increasingly disposable culture.

Still haven’t found a glue gun you can stick to? Try building your own.

3D Printed Battery Pack Keeps Old Drill Spinning

January 29, 2018 by Tom Nardi 12 Comments

The greatest enemy of proprietary hardware and components is time. Eventually, that little adapter cable or oddball battery pack isn’t going to be available anymore, and you’re stuck with a device that you can’t use. That’s precisely what happened to [Larry G] when the now antiquated 7.2V NiCd batteries used by his cordless drill became too hard to track down. The drill was still in great shape and worked fine, but he couldn’t power the thing. Rather than toss a working tool, he decided to 3D print his own battery pack.

The 3D modeling on the battery pack is impeccable

He could have just swapped new cells into his old pack, but if you’re going to go through all that trouble, why not improve on things a little? Rather than the NiCd batteries used by the original pack, this new pack is designed around readily available AA NiMH batteries. For the light repairs and craft work he usually gets himself into, he figures these batteries should be fine. Plus he already had them on hand, and as we all know, that’s half the battle when putting a project together.

Interestingly, the original battery pack was wired in such a way that it provided two voltages. In older tools such as this one, this would be used for rudimentary speed control. Depending on which speed setting the drill is on, it would either connect to 4 or 6 cells in the original pack. [Larry] didn’t want to get involved with the extra wiring and never used the dual speeds anyway, so his pack only offers the maximum speed setting. Though he does mention that it may be possible to do PWM speed control in the battery itself via a 555 timer if he feels like revisiting the project.

[Larry] tells us the pack itself was rendered completely from scratch, using only the original battery pack and trial-and-error to get the fit perfect. He reused the side-mounted release buttons to save time, but otherwise everything is 3D printed in PETG for its strength and chemical resistance.

This is an entry in Hackaday’s

Repairs You Can Print contest

The twenty best projects will receive $100 in Tindie credit, and for the best projects by a Student or Organization, we’ve got two brand-new Prusa i3 MK3 printers. With a printer like that, you’ll be breaking stuff around the house just to have an excuse to make replacement parts.

Hackaday Links: January 28, 2018

January 28, 2018 by Brian Benchoff 14 Comments

In case you haven’t heard, we have a 3D printing contest going on right now. It’s the Repairs You Can Print Contest. The idea is simple: show off how you repaired something with a 3D printer. Prizes include $100 in Tindie credit, and as a special prize for students and organizations (think hackerspaces), we’re giving away a few Prusa i3 MK3 printers.

[Drygol] has made a name for himself repairing various ‘home’ computers over the years, and this time he’s back showing off the mods and refurbishments he’s made to a pile of Amiga 500s. This time, he’s installing some new RAM chips, fixing some Guru Meditations by fiddling with the pins on a PLCC, adding a built-in modulator, installing a dual Kickstart ROM, and installing a Gotek floppy adapter. It’s awesome work that puts all the modern conveniences into this classic computer.

Here’s an FPGA IoT Controller. It’s a Cyclone IV and a WiFi module stuffed into something resembling an Arduino Mega. Here’s the question: what is this for? There are two reasons you would use an FPGA, either doing something really fast, or doing something so weird normal microcontrollers just won’t cut it. I don’t know if there is any application of IoT that overlaps with FPGAs. Can you think of something? I can’t.

Tide pods are flammable.

You know what’s cool? Sparklecon. It’s a party filled with a hundred pounds of LEGO, a computer recycling company, a plasmatorium, and a hackerspace, tucked away in an industrial park in Fullerton, California. It’s completely chill, and a party for our type of people — those who like bonfires, hammer Jenga, beer, and disassembling fluorescent lamps for high voltage transformers.

A few shoutouts for Sparklecon. The 23b Hackerspace is, I guess, the main host here, or at least the anchor. Across the alley is NUCC, the National Upcycled Computing Collective. They’re a nonprofit that takes old servers and such, refurbishes them, and connects them to projects like Folding@Home and SETI@Home. This actually performs a service for scientists, because every moron is mining Bitcoin and Etherium now, vastly reducing the computational capabilities of these distributed computing projects. Thanks, OSH Park, for buying every kind of specialty pizza at Pizza Hut. I would highly encourage everyone to go to Sparklecon next year. This is the fifth year, and it’s getting bigger and better every time.