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461 Articles

Mechanical 7-Segment Display Combines Servos And Lego

June 25, 2025 by 4 Comments

If you need a seven-segment display for a project, you could just grab some LED units off the shelf. Or you could build something big and electromechanical out of Lego. That’s precisely what [upir] did, with attractive results.

The build relies on Lego Technic parts, with numbers displayed by pushing small black axles through a large yellow faceplate. This creates a clear and easy to read display thanks to the high contrast. Each segment is made up of seven axles that move as a single unit, driven by a gear rack to extend and retract as needed. By extending and retracting the various segments in turn, it’s possible to display all the usual figures you’d expect of a seven-segment design.

It’s worth noting, though, that not everything in this build is Lego. The motors that drive the segments back and forth are third-party components. They’re Geekservo motors, which basically act as Lego-mountable servos you can drive with the electronics of your choice. They’re paired with an eight-channel servo driver board which controls each segment individually. Ideally, though, we’d see this display paired with a microcontroller for more flexibility. [upir] leaves that as an exercise for the viewer for now, with future plans to drive it with an Arduino Uno.

Design files are on Github for the curious. We’ve featured some similar work before, too, because you really can build anything out of Lego. Video after the break.

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Mark Setrakian and Adam Savage investigate a massive prop hand

17 Year Old Hellboy II Prop Still Amazes

May 30, 2025 by 7 Comments

The AI effects we know these days were once preceded by CGI, and those were once preceded by true hand-built physical props. If that makes you think of Muppets, this video will change your mind. In a behind-the-scenes look with [Adam Savage], effects designer [Mark Setrakian] reveals the full animatronic glory of Mr. Wink’s mechanical fist from Hellboy II: The Golden Army (2008) – and this beast still flexes.

Most of this arm was actually made in 2003, when 3D printing was very different than what we think of today. Printed on a Stratasys Titan – think: large refrigerator-sized machine, expensive as sin – the parts were then hand-textured with a Dremel for that war-scarred, brutalist feel. This wasn’t just basic animatronics for set dressing. This was a fully actuated prop with servo-driven finger joints, a retractable chain weapon, and bevel-geared mechanisms that scream mechanical craftsmanship.

Each finger is individually designed. The chain reel: powered by a DeWalt drill motor and custom bevel gear assembly. Every department: sculptors, CAD modelers, machinists, contributed to this hybrid of analog and digital magic. Props like this are becoming unicorns.

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[Austin Blake] sitting on line follower cart in garage

Honey, I Blew Up The Line Follower Robot

May 21, 2025 by 6 Comments

Some readers may recall building a line-following robot during their school days. Involving some IR LEDs, perhaps a bit of LEGO, and plenty of trial-and-error, it was fun on a tiny scale. Now imagine that—but rideable. That’s exactly what [Austin Blake] did, scaling up a classroom robotics staple into a full-size vehicle you can actually sit on.

The robot uses a whopping 32 IR sensors to follow a black line across a concrete workshop floor, adjusting its path using a steering motor salvaged from a power wheelchair. An Arduino Mega Pro Mini handles the logic, sending PWM signals to a DIY servo. The chassis consists of a modified Crazy Cart, selected for its absurdly tight turning radius. With each prototype iteration, [Blake] improved sensor precision and motor control, turning a bumpy ride into a smooth glide.

The IR sensor array, which on the palm-sized vehicle consisted of just a handful of components, evolved into a PCB-backed bar nearly 0.5 meters wide. Potentiometer tuning was a fiddly affair, but worth it. Crashes? Sure. But the kind that makes you grin like your teenage self. If it looks like fun, you could either build one yourself, or upgrade a similar LEGO project.
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Multifunctional USB controlled PCB on blue background

How A Tiny Relay Became A USB Swiss Army Knife

April 5, 2025 by 17 Comments

Meet the little board that could: [alcor6502]’s tiny USB relay controller, now evolved into a multifunction marvel. Originally built as a simple USB relay to probe the boundaries of JLCPCB’s production chops, it has become a compact utility belt for any hacker’s desk drawer. Not only has [alcor6502] actually built the thing, he even provided instructions. If you happened to be at Hackaday in Berlin, you now might even own one, as he handed out twenty of them during his visit. If not, read on and build it yourself.

This thing is not just a relay, and that is what makes it special. Depending on a few solder bridges and minimal components, it shape-shifts into six different tools: a fan controller (both 3- and 4-pin!), servo driver, UART interface, and of course, the classic relay. It even swaps out a crystal oscillator for USB self-sync using STM32F042‘s internal RC – no quartz, less cost, same precision. A dual-purpose BOOT0 button lets you flash firmware and toggle outputs, depending on timing. Clever reuse, just like our mothers taught us.

It’s the kind of design that makes you want to tinker again. Fewer parts. More function. And that little smile when it just works. If this kind of clever compactness excites you too, read [alcor6502]’s build log and instructions here.

The Mysterious And Important Work Of Prop Design On Severance

March 13, 2025 by 28 Comments

Have you seen Severance? Chances are good that you have; the TV series has become wildly popular in its second season, to the point where the fandom’s dedication is difficult to distinguish from the in-universe cult of [Kier]. Part of the show’s appeal comes from its overall aesthetic, which is captured in this description of the building of one of the show’s props.

A detailed recap of the show is impossible, but for the uninitiated, a mega-corporation called Lumon has developed a chip that certain workers have implanted in their brains to sever their personalities and memories into work and non-work halves. The working “Innies” have no memory of what their “Outies” do when they aren’t at work, which sounds a lot better than it actually ends up being. It’s as weird as it sounds, and then some.

The prop featured here is the “WoeMeter” from episode seven of season two, used to quantify the amount of woe in a severed worker — told you it was weird. The prop was built by design house [make3] on a short timeline and after seeing only some sketches and rough renders from the production designers, and had to echo the not-quite-midcentury modern look of the whole series. The builders took inspiration from, among other things, a classic Nagra tape recorder, going so far as to harvest its knobs and switches to use in the build. The controls are all functional and laid out in a sensible way, allowing the actors to use the device in a convincing way. For visual feedback, the prop has two servo-operated meters and a string of seven-segment LED displays, all controlled by an ESP-32 mounted to a custom PCB. Adding the Lumon logo to the silkscreen was a nice touch.

The prop maker’s art is fascinating, and the ability to let your imagination run wild while making something that looks good and works for the production has got to be a blast. [make3] really nailed it with this one.

Thanks to [Aaron’s Outie] for the tip.

Gimbal Clock Relies On Servos For Its Cool Movements

January 16, 2025 by 1 Comment

In the annals of human history, clocks got boring there for a while. Most were just variations on hands spinning in a circle, with the occasional tweeting bird mechanism to liven things up. These days, we’re treated to all kinds of original and oddball designs, like this neat gimbal clock from [Twisted&Tinned].

The concept of the build is straightforward enough. It has four main vertical arms, each with a servo at the base that rotates about a vertical axis. Upon each arm are between one and three servos which rotate 3D printed structures in the shape of numbers. A Wemos D1 Mini microcontroller commands the servos to the correct positions to display the current time. It also uses its WiFi connection to get accurate time updates directly from a network time server.

It’s quite an artistic build—and it’s rather enjoyable to watch this one flex and twist its way into displaying the right time. It’s also easier to read at a glance than some of the more unintelligible designs out there. Indeed, we see all kinds of neat and innovative clocks around these parts.

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Gas Gauge Upgrade Keeps VW Restoration Classy

December 4, 2024 by 49 Comments

Getting every detail perfectly right is often the goal in automotive restorations, and some people will go to amazing lengths to make sure the car looks and acts just like it did when it rolled off the dealer’s lot all those decades ago. That ethos can be pushed a little too far, though, especially with practical matters like knowing how much gas is left in the tank. Get that wrong and you’ll be walking.

Unwilling to risk that cruel fate with his restoration of 1978 Volkswagen Bus, [Pegork] came up with a replacement fuel gauge that looks identical to the original meter, but actually works. The gas gauges on ’60s and ’70s VWs were notoriously finicky, and when they bothered to work at all they were often wildly inaccurate. The problem was usually not with the sender unit in the tank, but the gauge in the dash, which used a bimetallic strip heated by a small coil of wire to deflect a needle. [Pegor]’s “SmoothBus” modification replaces the mechanical movement with a micro servo to move the needle. The variable voltage coming back from the fuel sender is scaled through a voltage divider and read by an analog input on an ATtiny85, which does a little algorithmic smoothing to make sure the needle doesn’t jump around too much. A really nice addition is an LED low fuel indicator, a feature that would have saved us many walks to the gas station back in our VW days. Except for the extra light, the restored gauge looks completely stock, and it works far better than the original.

Hats off to [Pregor] for this fantastic restomod. As we’ve noted before, classic VWs are perhaps the most hackable of cars, and we applaud any effort to keep these quirky cars going.