Repurposed Plastic Protects PCBs

June 6, 2019 by Brian McEvoy 28 Comments

An errant wire snipping across the wrong electrical pins spells the release of your magic smoke. Even if you are lucky, stray parts are the root of boundless malfunctions from disruptive to deadly. [TheRainHarvester] shares his trick for covering an Arduino Nano with some scrap plastic most of us have sitting in the recycling bin. The video is also after the break. He calls this potting, but we would argue it is a custom-made cover.

The hack is to cut a bit of plastic from food container lids, often HDPE or plastic #2. Trim a piece of it a tad larger than your unprotected board, and find a way to hold it in place so you can blast it with a heat gun. When we try this at one of our Hackaday remote labs and apply a dab of hot glue between the board and some green plastic it works well. The video suggests a metal jig which would be logical when making more than one. YouTube commenter and tip submitter [Keith o] suggests a vacuum former for a tighter fit, and we wouldn’t mind seeing custom window cutouts for access to critical board segments such as DIP switches or trimmers.

We understand why shorted wires are a problem, especially when you daisy-chain three power supplies as happened in one of [TheRainHarvester]’s previous videos.

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TréPhonos Calls Up History In Houston

February 8, 2019 by Brian McEvoy 7 Comments

Houston’s historic third ward, aka “The Tre,” is ~~ripe~~ rife with history, and some of that history is digitally preserved and accessible through an art installation in the form of repurposed payphones. We love payphones for obvious reasons and seeing them alive and kicking warms our hearts. Packing them with local history checks even more boxes. Twenty-four people collaborated to rebuild the three phones which can be seen in the video after the break, including three visual artists, three ambassadors, and eighteen residents who put their efforts into making the phones relevant not only to the ward but specifically to the neighborhood. One phone plays sound clips from musicians who lived or still live in the ward, another phone has spoken word stories, and the third has field recordings from significant locations in The Tre.

Each phone is powered by a solar cell and a USB battery pack connected to a Teensy with an audio adapter board, and a 20 watt amplifier. Buttons 1-9 play back recorded messages exclusive to each phone, star will record a message, and zero will play back the user-recorded message. Apps for smart phones are easy for young folks to figure out but the payphones ensure that these time capsules can be appreciated by people of any age, regardless of how tech savvy they are and that is wise as well as attractive. The coin return lever and coin slot also have associated sound clips unlike regular payphones so the artists get extra credit.

Did we say that we love payphones? Yes, yes we did. The very first post on Hackday was for a redbox and that got the ball rolling.

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Sorter Uses Cardboard To Organize Card Hoard

January 26, 2019 by Kristina Panos 13 Comments

If you collect trading cards of any kind, you know that storage quickly becomes an issue. Just ask [theguymasamato]. He used to be really into trading cards, and got back into it when his kids caught the bug. Now he’s sitting on 10,000+ cards that are largely unorganized except for a few that made it into sleeve pages. They tried to go through them by hand, but only ended up frustrated and overwhelmed. Then he found out about [Michael Portera]’s Pi-powered LEGO card sorter and got all fired up to build a three-part system that feeds cards in one by one, scans them, and sorts them into one of 22 meticulously-constructed cardboard boxes.

[theguymasamato]’s card sorter is the last stop for a card after the feeder has fed it in from the pile and the scanner has scanned it. The sorter lazy Susans around on a thrust bearing, which is driven by a 3D printed drive wheel attached to a stepper. The stepper is controlled with an Arduino.

Here’s where it gets crazy: the drive wheel and timing belt are made from the flutes of corrugated cardboard. As in, he used that wavy bit in the middle as gear teeth. Every one of those cardboard teeth is fortified with wood glue, a time-consuming process he vows to never repeat. Instead, [theguymasamato] recommends using shims to shore them up as he did in the card feeder. The whole thing was originally going to be made from cardboard. It proved to be too mushy to support the thrust bearing, so [theguymasamato] switched to MDF.

Right now, the sorter is homed via button press, but future plans for the device include an IR break beam switch. We’re excited for the scanner and can’t wait to see the whole system put together. While [theguymasamato] works on that, position yourself past the break to watch the build video.

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Roll Your Own Trackball Mouse

June 23, 2018 by Kristina Panos 7 Comments

What do you do when you’re into trackball mice, but nothing out there is affordable or meets all your murine needs? You build one, of course. And if you’re like [Dangerously Explosive], who has a bunch of old optical mice squeaking around the shop, you can mix and match them to build the perfect one.

The mouse, which looks frozen mid-transformation into a rodential assassin, is a customized work of utilitarian art. Despite the excellent results, this project was not without its traps. [Dangerously] got really far into the build before discovering the USB interface chip was dead. Then he tried to sculpt a base out of Plasticine and discovered he’d bought the one kind of clay that can’t be baked. After trying his hand at making homemade salt dough, he painstakingly whittled a base from scrap pine using a drill and a hacksaw.

Every bit of this mouse is made from recycled bits, which, if you pair that with the paint job and the chosen shade of blinkenlights, makes this a green mouse on three levels. One of the two parts of this mouse that isn’t literally green, the cord, is still ecologically sound. [Dangerously] wanted a really long tail, so he scavenged a charger cable built for fruity hardware and threaded it through a hollowed-out piece of purple paracord.

We love the thumb-adjacent scroll wheel and the trackball itself, which is a ping pong ball painted black. The cool part is the guide it rolls around in. [Dangerously] spent a long time hand-whittling the perfect size hole in a particularly wide mouse palm rest. All that plastic shaving paid off, because the action is smooth as Velveeta.

[Dangerously] certainly designed this mouse to fit his preferences, and ergonomics seem a bit secondary. For a truly custom fit, try using whatever passes for Floam these days.

Laser Cutter Turns Scrapped To Shipped

June 19, 2018 by Tom Nardi 25 Comments

We’ll go way out on a limb here and say you’ve probably got a ridiculous amount of flattened cardboard boxes. We’re buying more stuff online than ever before, and all those boxes really start to add up. At the least we hope they’re making it to the recycling bin, but what about reusing them? Surely there’s something you could do with all those empty shipping boxes…

Here’s a wild idea…why not use them to ship things? But not exactly as they are, unless you’re in the business of shipping big stuff, the probably won’t do you much good as-is. Instead, why not turn those big flattened cardboard boxes into smaller, more convenient, shippers? That’s exactly what [Felix Rusu] has done, and we’ve got to say, it’s a brilliant idea.

[Felix] started by tracing the outline of the USPS Priority Small Flat Rate Box, which was the perfect template as it comes to you flat packed and gets folded into its final shape. He fiddled with the design a bit, and in the end had a DXF file he could feed into his 60W CO2 laser cutter. By lowering the power to 15% on the fold lines, the cutter is even able to score the cardboard where it needs to fold.

Assuming you’ve got a powerful enough laser, you can now turn all those Amazon Prime boxes into the perfect shippers to use when your mom finally makes you sell your collection of Yu-Gi-Oh! cards on eBay. Otherwise, you can just use them to build a wall so she’ll finally stay out of your side of the basement.

[Thanks to Adrian for the tip.]

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Broken Screen Becomes Polarizing Art Lamp

May 9, 2018 by Kristina Panos 7 Comments

Got a broken laptop screen sitting around? If you haven’t already pilfered the LEDs and used the polarizing sheets for screen privacy filters, why not turn it into a unique table lamp? See if you can use more parts of the screen than [alexmaree-ross] did.

This is a simple idea with great-looking results, but the process is a bit fiddly. After all the layers are separated and the LEDs extracted, there’s still the matter of figuring out how they’re wired up. [alexmaree] tested them in pairs to see how they’re grouped together and ultimately powered them with a transformer from an old printer. To build the case, [alexmaree] carefully scored and snapped the pieces from the plastic layer and carefully glued pieces of the polarizing layer on top to give it that underwater infinity mirror look. The finishing touch comes from edging the shade with thin metal from the bezel.

The case could be in any shape you want, but we think the prism is quite appropriate considering the polarizing effects. And it looks really cool when you walk around it, which you can do vicariously after the break.

If the screen still works but laptop doesn’t, why not drive it with an FPGA?

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DIY Designer Wallet From Designer Bag

April 9, 2018 by Kristina Panos 13 Comments

Why do people drop hundreds of dollars on designer goods? The easy answer is that, in theory, the goods are worth the expense. The materials, craftsmanship, and attention to detail are all top-notch and culminate in the finest finery money can buy.

So, would you spend hundreds of dollars on a designer wallet? If you have leather crafting skills and a thrift store nearby, you could just follow [Corter Leather]’s example and make your own. He found a diamond in the rough—a genuine, well-loved Louis Vuitton bag languishing in a secondhand shop. The leather bottom and handles were dry and worn, but the signature LV canvas was still in great shape. Never crafted leather? If you can’t get free scraps for practicing, then deconstructing cheap, used stuff is the next best thing.

To isolate the canvas, [Corter] carefully removed the bag’s handles, bottom, liner, and zipper and then popped the rivets and peeled the backing from the fabric. He drew up a pattern in Illustrator that pays homage to the illustrious designer’s wallets and cut the pieces out of 3oz vegetable tanned leather using card stock templates.

[Corter] brought his A-game to the details. Every visible edge is painted Italian red, which he applied with an awl for a crisp line. The larger pockets have hidden stitches that keep cards from drifting to the bottom and throwing off the shape. No need to open your wallet to see how he did it—just watch the video after the break.

Though it technically isn’t a real Louis Vuitton, a thief wouldn’t know it until later. Maybe [Corter] should add a pickpocket alarm.

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