Ask Hackaday: What Do You Do When You Can’t Solder?

December 18, 2023 by Lewin Day 93 Comments

Ah, soldering. It’s great for sticking surface mount parts to a PCB, and it’s really great for holding component legs in a plated through-hole. It also does a pretty great job of holding two spliced wires together.

With that said, it can be a bit of a fussy process. There are all manner of YouTube videos and image tutorials on the “properest” way to achieve this job. Maybe it’s the classic Lineman’s Splice, maybe it’s some NASA-approved method, or maybe it’s one of those ridiculous ones where you braid all the copper strands together, solder it all up, and then realize you’ve forgotten to put the heat shrink on first.

Sure, soldering’s all well and good. But what about some of the other ways to join a pair of wires?

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Hackaday Links: April 30, 2023

April 30, 2023 by Dan Maloney 17 Comments

Cloudy with a chance of concrete? The “success” of last week’s brief but eventful Starship launch has apparently raised some regulatory eyebrows, with the Federal Aviation Administration launching an investigation into the destruction wrought by the mighty rocket. And it’s not just the hapless Dodge Caravan that they’re concerned with — although we found some fantastic POV footage that shows the kill shot as well as close-ups of the results — but also the damage rained down upon residents around the Boca Chica launch complex. Tons of concrete and rebar were excavated by the 33 Raptor engines during the launch and sent in all directions, reportedly landing up to 6 miles (10 kilometers) from the pad. What’s worse, a lot of debris ended up on beaches that are home to endangered species, which has the Sierra Club also taking an interest. The FAA has apparently nixed any launches from the Texas facility until they complete their investigation.

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Print-in-Place Connectors Aim To Make Wiring Easier

February 15, 2021 by Dan Maloney 115 Comments

One thing some of us here in the United States have always been jealous of is the WAGO connectors that seem so common in electrical wiring everywhere else in the world. We often wonder why the electrical trades here haven’t adopted them more widely — after all, they’re faster to use than traditional wire nuts, and time is money on the job site.

Wago 221 compact lever connector via the Wago YouTube channel

This print-in-place electrical connector is inspired by the WAGO connectors, specifically their Lever Nut series. We’ll be clear right up front that [Tomáš “Harvie” Mudruňka’s] connector is more of an homage to the commercially available units, and should not be used for critical applications. Plus, as a 3D-printed part, it would be hard to compete with something optimized to be manufactured in the millions. But the idea is pretty slick. The print-in-place part has a vaguely heart-shaped cage with a lever arm trapped inside it.

After printing and freeing the lever arm, a small piece of 1.3-mm (16 AWG) solid copper wire is inserted into a groove. The wire acts as a busbar against which the lever arm squeezes conductors. The lever cams into a groove on the opposite wall of the cage, making a strong physical and electrical connection. The video below shows the connectors being built and tested.

We love the combination of print-in-place, compliant mechanisms, and composite construction on display here. It reminds us a bit of these printable SMD tape tamers, or this print-in-place engine benchmark.

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