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RepRapMicron Uses Fibre Optics To Print Tiny Benchy in Resin

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The 0.5 mm Benchy made with the MicroRepRap UV head. The RepRapMicron (also µRepRap) is pretty much the microscopic take on what RepRap did for more macroscale manufacturing, with the most recent innovation being a UV print head, called the PIKA UV Head . What this does is use off-the-shelf optical fiber and UV LED modules to create 3D structures in-situ in a UV resin, allowing for pretty small structures to be printed, down to a resolution of about 9 µm. More photos of prints can be found on the blog page with links to YouTube videos. It’s naturally somewhat tricky to get clean photographs of a 3D print that’s small enough to lose forever if you so much as sneeze or breathe too loudly. For the UV head assembly a single mode fiber optical cable was used in the form of a regular patch cord that got trimmed a bit with a hacksaw. This was used in combination with a “3W” UV LED module, which may or may not be its true rating, but it was definitely able to cure th...

Automatic Coil Winder Takes the Tedium out of Actuators

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Anyone who’s ever built their own motors knows how tedious winding the coils soon becomes; in [Larry]’s case, the issue was even worse. He’s building his own flip-dot matrix display, and each dot uses two electromagnetic coils to flip a magnet in the dot. Rather than wind each of these by hand, therefore, he built his own coil-winding machine . The coil winder uses two stepper motors: one to wind wire onto the bobbin, and one to move the wire guide carriage back and forth, distributing the wire evenly across the bobbin. The bobbin is held in place by a retainer, which doubles as a tie point for the end of the wire. The spool of wire rotates on a pair of bearings, and the wire is fed between two pieces of foam to provide adjustable tension. The housing is mostly 3D-printed, with some metal rods, bearings, and belt drives fleshing out the structure. On the electronics side, a Teensy controls the winder, with an OLED display and a rotary encoder for control. Before beginning on a coil, ...

Reconstructing the Ancient Chinese Storm of Crows Weapon

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The Chinese had been using large crossbows – akin to Greek and Roman ballistae – for warfare for many of the same reasons that European armies loved them. Their single, large arrow was effectively unstoppable, though this also was rather useless against large groups of infantry unless they were so kind to neatly line up. Old Chinese records mention a special kind of ammunition, called a cup arrow, or ‘storm of crows’, which involves launching many smaller arrows instead of a single large one, a feat that [Tod] really wanted to try and recreate . In itself this doesn’t sound too complex: just grab some arrows, loosely tie them together in a bundle and slap them on the crossbow. Yet with the immense forces applied on this bundle it clearly turns out that the engineering challenge isn’t quite that straightforward, as the arrows love to scatter wildly in all directions or otherwise be rather unpredictable. Although we can find historical references to ...

Running a Philips CD-i Off USB-C

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The Philips CD-i is a console with many shortcomings, and those include the power supply. For whatever reason, the engineering team decided it should use an 8P8C connector just like Ethernet. Thus, just like your Ethernet cables, it has that annoying problem of the tab snapping off all the time. [MattKC] wondered if the CD-i could benefit from a USB power upgrade instead, and set about making it a reality. The plan was simple enough—get the CD-i running off of USB-C instead of the ungainly original power supply that shipped with the unit. Given the console runs almost exclusively off of 5 V power, it should have been pretty easy. Only, the original spec adds one little detail that makes things a bit harder. The console is designed to draw up to 3 A from the 5 V line, while also having a -5 V line at 0.2 A. If not for that negative supply, it would have been easy to run the unit off any old 15 W USB-C charger spitting out 5 V. That extra negative line complicates things, because while ...

NASA Batteries Survive Extreme Cold and Heat

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One of the major limits of mass-produced batteries is the electrolyte. From lead-acid to lithium ion, there’s some temperature where the electrolyte will freeze and cause all sorts of problems, from cracked casings to various non-favorable chemical changes in the battery itself. But if there’ a solid electrolyte available, many of the downsides of charging and discharging batteries in extreme cold disappear. These batteries developed by NASA, for example, can survive some wild temperature swings . The electrolytes used for these batteries are either a ceramic or polymer electrolyte, both of which are solid. In testing, the batteries could meaningfully operate at temperatures of -60° C and up to 80 ° C on the high end. Further, the solid electrolyte helps protect them even outside of these temperature ranges. Bringing the battery temperature down to -170 ° C was not enough to damage the battery at all, and using a small heater to bring the temperature back up to its operat...

Car’s Camera Footage Backed up to NAS

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For as many sensors, cameras, and computers as there are on modern cars, they ought to be a dream to poke around in and customize to one’s liking. Unfortunately they’re generally plagued by the same locked-down, proprietary software that most consumer electronics ship with, making it very difficult to interact with these systems in ways the manufacturer doesn’t approve of. There are a few exceptions to this rule, though, and [Sasha] built this system which backs up the footage from their electric car’s on-board cameras automatically to a NAS . The system is built around a Raspberry Pi Zero 2 W which plugs directly into a USB port in the car’s glovebox. To set it up, the software only needs to be flashed onto the Pi and then it can be controlled from a smartphone. It can connect to any NAS over a variety of protocols and keeps track of what footage has been backed up, and can even automatically restart a backup if the car drives away before it has completed...

An Open Source Linear Capacitive Encoder

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If you’ve ever pulled apart a set of digital calipers, you’ve probably marvelled at the capacitive encoder that does all the measuring work. There’s nothing stopping you from using the same techniques yourself, as [Nick] demonstrates with an open-source capacitive encoder of his own design. The sensor PCB works by by having a grid of eight transmitting antennas, etched into a PCB, beneath a larger receiving antenna. The transmitting antennas pulse out a pattern as the sensor PCB moves, with the signals bouncing back from the reflector PCB which is fixed in place. The varying capacitance caused by the position of the reflector elements relative to the sensor PCB varies the strength of the pulses hitting the receiving antenna. A microcontroller—in this case an STM32—can read those pulses to determine the displacement of the sensor PCB relative to the reflector down to a very fine degree. In this case, to an accuracy of 40 micrometers. Not bad! If you need ultra-fine li...