Author: Aaron Beckendorf

73 Articles

Two geared plastic disks can be seen on a platform. One disk rotates around a central column, while the other is mounted on a platform that extends from the edge of the first disk. The second disk holds a print bed, and a print head mounted on the column is positioned just above a half-finished 3D print.

A Toolchanging Inverse SCARA 3D Printer

October 18, 2025 by 17 Comments

There are some times when a picture, or better yet a video, really is worth a thousand words, and [heinz]’s dual-disk polar 3D printer is one of those projects. Perhaps the best way to describe it is as an inverted SCARA system that moves the print bed around the hot end, producing strange and mesmerizing motion paths.

The Z-axis runs on a column through the center of the printer, while the print bed is a geared disk that can independently rotate both around its own center and around the central column. This gives the printer a simple way to use multiple extruders: simply mount the extruders at different angles around the central pillar, then rotate the bed around to whichever extruder is currently in use. (See the video demo below.) Since the extruder only moves in the Z direction, there’s also no need to make it as light as possible. In one test, it worked perfectly well with a five-filament direct-drive extruder assembly weighing two kilograms, though it proved a bit unwieldy.

[heinz] 3D printed the rotating disks and a few other parts of the printer, and used two GT2 timing pulleys and the bearings from a Lazy Susan to drive the disks and let them rotate. The print bed’s surface is made out of fiberglass, and since it’s unheated, it has a pattern of small holes drilled into it to let molten plastic seep in and adhere. One nice side effect of the rotating print bed is that it can produce a turntable effect on time-lapse videos.

We’ve covered this project once before when it was a bit earlier in development, and somehow we missed when it got upgraded to its current status. Let’s just say we’re impressed!

Polar 3D printers may make it a bit harder to visualize paths, but they can do unique things like print with four heads at a time or print in non-planar paths.

Continue reading “A Toolchanging Inverse SCARA 3D Printer” →

An array of tiny parallel green lines appears over a steel surface. The white dot a laser beam is visible in the lower center of the picture.

A New Way To Make (Almost) Holograms With Lasers

October 17, 2025 by 6 Comments

The spectrum of laser technologies available to hackers has gradually widened from basic gas lasers through CO2 tubes, diode lasers, and now fiber lasers. One of the newer entries is the MOPA laser, which combines a laser diode with a fiber-based light amplifier. The diode’s pulse length and repetition rate are easy to control, while the fiber amplifier gives it enough power to do interesting things – including, as [Ben Krasnow] found, etch hologram-like diffraction gratings onto stainless steel.

Stainless steel works because it forms a thin oxide layer when heated, with a thickness determined by the temperature it reaches. The oxide layer creates thin-film interference with incoming light, letting the laser mark parts of a steel sheet with different colors by varying the intensity of heating. [Ben] wrote a script to etch color images onto steel using this method, and noticed in one experiment that one area seemed to produce diffraction patterns. More experimentation revealed that the laser could consistently make diffraction gratings out of parallel patterns of oxide lines. Surprisingly, the oxide layer seemed to grow mostly down into the metal, instead of up from the surface.

The pitch of the grating is perpendicular to the direction of the etched lines, and varying the line spacing changes the angle of diffraction, which should in theory be enough control to print a hologram with the laser. [Ben]’s first experiment in this general direction was to create a script that turned black-and-white photographs into shimmering matrices of diffraction-grating pixels, in which each pixel’s grating orientation was determined by its brightness. To add a parallax depth effect, [Ben] spread out images into a gradient in a diffraction grating, so that it produced different images at different angles. The images were somewhat limited by the minimum size required for the grating pixels, but the effect was quite noticeable.

Unfortunately, since the oxide layers grow down into the metal, [Ben] doubts whether the laser can etch molds for diffraction-grating chocolate. If you’re interested in more diffraction optics, check out these custom diffraction lenses or the workings of normal holograms.

A metal needle tip comes to a point against a white background. A scale bar in the lower left shows a 300 micrometer length.

Etching Atomically Fine Needle Points

October 13, 2025 by 22 Comments

[Vik Olliver] has been extending the lower resolution limits of 3D printers with the RepRapMicron project, which aims to print structures with a feature size of ten micrometers. A molten plastic extruder would be impractical at such small scales, even if a hobbyist could manufacture one small enough, so instead [Vik]’s working on a system that uses a very fine needle point to place tiny droplets of UV resin on a substrate. These points have to be sharper than anything readily available, so his latest experiments have focused on electrochemically etching his own needles.

The needles start with a fine wire, which a 3D-printed bracket holds hanging down into a beaker of electrolyte, where another electrode is located. By applying a few volts across the circuit, with the wire acting as an anode, electrochemical erosion eventually wears through the wire and it drops off, leaving an atomically sharp point. Titanium wire performs best, but Nichrome and stainless steel also work. Copper wire doesn’t work, and by extension, nor does the plated copper wire sometimes sold as “stainless steel” by sketchy online merchants.

The electrolyte was made from either a 5% sodium chloride solution or 1% nitric acid. The salt solution produced a very thin, fine point, but also produced a cloudy suspension of metal hydroxides around the wire, which made it hard to tell when the wire had broken off. The goal of nitric acid was to prevent hydroxide formation; it produced a shorter, blunter tip with a pitted shaft, but it simply etched the tip of the wire to a point, with the rest of the wire never dropping off. Some experimentation revealed that a mixture of the two electrolyte solutions struck a good balance which etched fine points like the pure salt solution, but also avoided cloudy precipitates.

If you’re interested in seeing more of the RepRapMicron, we’ve looked at a previous iteration which scribed a minuscule Jolly Wrencher in marker ink. On a more macro scale, we’ve also seen one 3D printer which used a similar resin deposition scheme.

A vertically-mounted black disk with a concentric pattern of reflective disks is illuminated under a red light. A large number of copper wires run away from the the disk to a breadboard.

Deforming A Mirror For Adaptive Optics

October 13, 2025 by 16 Comments

As frustrating as having an atmosphere can be for physicists, it’s just as bad for astronomers, who have to deal with clouds, atmospheric absorption of certain wavelengths, and other irritations. One of the less obvious effects is the distortion caused by air at different temperatures turbulently mixing. To correct for this, some larger observatories use a laser to create an artificial star in the upper atmosphere, observe how this appears distorted, then use shape-changing mirrors to correct the aberration. The physical heart of such a system is a deformable mirror, the component which [Huygens Optics] made in his latest video.

The deformable mirror is made out of a rigid backplate with an array of linear actuators between it and the thin sheet of quartz glass, which forms the mirror’s face. Glass might seem too rigid to flex under the tenth of a Newton that the actuators could apply, but everything is flexible when you can measure precisely enough. Under an interferometer, the glass visibly flexed when squeezed by hand, and the actuators created enough deformation for optical purposes. The actuators are made out of copper wire coils beneath magnets glued to the glass face, so that by varying the polarity and strength of current through the coils, they can push and pull the mirror with adjustable force. Flexible silicone pillars run through the centers of the coils and hold each magnet to the backplate.

A square wave driven across one of the actuators made the mirror act like a speaker and produce an audible tone, so they were clearly capable of deforming the mirror, but a Fizeau interferometer gave more quantitative measurements. The first iteration clearly worked, and could alter the concavity, tilt, and coma of an incoming light wavefront, but adjacent actuators would cancel each other out if they acted in opposite directions. To give him more control, [Huygens Optics] replaced the glass frontplate with a thinner sheet of glass-ceramic, such as he’s used before, which let actuators oppose their neighbors and shape the mirror in more complex ways. For example, the center of the mirror could have a convex shape, while the rest was concave.

This isn’t [Huygens Optics]’s first time building a deformable mirror, but this is a significant step forward in precision. If you don’t need such high precision, you can also use controlled thermal expansion to shape a mirror. If, on the other hand, you take it to the higher-performance extreme, you can take very high-resolution pictures of the sun.

A magnifying glass is seen behind a small tea candle. The magnifying image is projecting the shadow of a column of heated air.

Finding Simpler Schlieren Imaging Systems

October 6, 2025 by 3 Comments

Perhaps the most surprising thing about shadowgraphs is how simple they are: you simply take a point source of light, pass the light through a the volume of air to be imaged, and record the pattern projected on a screen; as light passes through the transition between areas with different refractive indices, it gets bent in a different direction, creating shadows on the viewing screen. [Degree of Freedom] started with these simple shadowgraphs, moved on to the more advanced schlieren photography, and eventually came up with a technique sensitive enough to register the body heat from his hand.

The most basic component in a shadowgraph is a point light source, such as the sun, which in experiments was enough to project the image of an escaping stream of butane onto a sheet of white paper. Better point sources make the imaging work over a wider range of distances from the source and projection screen, and a magnifying lens makes the image brighter and sharper, but smaller. To move from shadowgraphy to schlieren imaging, [Degree of Freedom] positioned a razor blade in the focal plane of the magnifying lens, so that it cut off light refracted by air disturbances, making their shadows darker. Interestingly, if the light source is small and point-like enough, adding the razor blade makes almost no difference in contrast.

With this basic setup under his belt, [Degree of Freedom] moved on to more unique schlieren setups. One of these replaced the magnifying lens with a standard camera lens in which the aperture diaphragm replaced the razor blade, and another replaced the light source and razor with a high-contrast black-and-white pattern on a screen. The most sensitive technique was what he called double-pinhole schlieren photography, which used a pinhole for the light source and another pinhole in place of the razor blade. This could image the heated air rising from his hand, even at room temperature.

The high-contrast background imaging system is reminiscent of this technique, which uses a camera and a known background to compute schlieren images. If you’re interested in a more detailed look, we’ve covered schlieren photography in depth before.

Thanks to [kooshi] for the tip!

A person's hand wearing a black glove is shown in the right part of the image, making a series of gestures. A representation of a hand mimics those motions on a laptop screen.

Weaving Circuits From Electronic Threads

October 6, 2025 by 6 Comments

Though threading is a old concept in computer science, and fabric computing has been a term for about thirty years, the terminology has so far been more metaphorical than strictly descriptive. [Cedric Honnet]’s FiberCircuits project, on the other hand, takes a much more literal to weaving technology “into the fabric of everyday life,” to borrow the phrase from [Mark Weiser]’s vision of computing which inspired this project. [Cedric] realized that some microcontrollers are small enough to fit into fibers no thicker than a strand of yarn, and used them to design these open-source threads of electronics (open-access paper).

The physical design of the FiberCircuits was inspired by LED filaments: a flexible PCB wrapped in a protective silicone coating, optionally with a protective layer of braiding surrounding it. There are two kinds of fiber: the main fiber and display fibers. The main fiber (1.5 mm wide) holds an STM32 microcontroller, a magnetometer, an accelerometer, and a GPIO pin to interface with external sensors or other fibers. The display fibers are thinner at only one millimeter, and hold an array of addressable LEDs. In testing, the fibers could withstand six Newtons of force and be bent ten thousand times without damage; fibers protected by braiding even survived 40 cycles in a washing machine without any damage. [Cedrik] notes that finding a PCB manufacturer that will make the thin traces required for this circuit board is a bit difficult, but if you’d like to give it a try, the design files are on GitHub.

[Cedrik] also showed off a few interesting applications of the thread, including a cyclist’s beanie with automatic integrated turn signals, a woven fitness tracker, and a glove that senses the wearer’s hand position; we’re sure the community can find many more uses. The fibers could be embroidered onto clothing, or embedded into woven or knitted fabrics. On the programming side, [Cedrik] ported support for this specific STM32 core to the Arduino ecosystem, and it’s now maintained upstream by the STM32duino project, which should make integration (metaphorically) seamless.

One area for future improvement is in power, which is currently supplied by small lithium batteries; it would be interesting to see an integration of this with power over skin. This might be a bit more robust, but it isn’t first knitted piece of electronics we’ve seen. Of course, rather than making wearables more unobtrusive, you can go in the opposite direction. Continue reading “Weaving Circuits From Electronic Threads” →

A man is shown behind a table, on which a glass apparatus like a distillation apparatus is set, with outlets leading into a large container in the center of the table, and from there to a pump.

Pulling A High Vacuum With Boiling Mercury

October 3, 2025 by 21 Comments

If you need to create a high vacuum, there are basically two options: turbomolecular pumps and diffusion pumps. Turbomolecular pumps require rotors spinning at many thousands of rotations per minute and must be carefully balanced to avoid a violent self-disassembly, but diffusion pumps aren’t without danger either, particularly if, like [Advanced Tinkering], you use mercury as your working fluid. Between the high vacuum, boiling mercury, and the previous two being contained in fragile glassware, this is a project that takes steady nerves to attempt – and could considerably unsteady those nerves if something were to go wrong.

Continue reading “Pulling A High Vacuum With Boiling Mercury” →