The Smell of Molten Projects in the Morning

Ed Nisley's Blog: Shop notes, electronics, firmware, machinery, 3D printing, laser cuttery, and curiosities. Contents: 100% human thinking, 0% AI slop.

Category: Science

If you measure something often enough, it becomes science

  • PolyDryer Humidity: October

    After a month with 50 g of alumina in each box:

    2026-10-13
    Filament%RHWeight – gWt gain – gGain %
    PETG-CF Black2153.13.16.2%
    PETG White2352.62.65.2%
    PETG Black2353.23.26.4%
    TPU Black2452.82.85.6%
    PETG Orange2752.92.95.8%
    PETG-CF Gray3053.33.36.6%
    TPU Clear3152.92.95.8%
    PETG Clear3353.33.36.6%
    PETG-CF Blue3053.73.77.4%
    PETG Blue2553.03.06.0%

    A day later, most of the boxes were in the 10%RH to 15%RH range, with the filament spools slowly releasing their stored moisture. The PETG Orange meter jumps between 10% and 27%, with the latter more believeable.

    Changing the desiccant every month, without thinking too hard, may be the simplest path to dry filament storage.

  • Printed Fragment Coaster: Delamination and Pinhole

    Printed Fragment Coaster: Delamination and Pinhole

    Although “chipboard” is also known as “beer mat”, it’s not intended for long-term use under sweaty mugs. After a few weeks of daily use, this is obviously out of spec:

    Printed Fragment Coaster - moisture damage
    Printed Fragment Coaster – moisture damage

    The aforementioned sweaty mug lifted part of a fragment off the coaster:

    Printed Fragment Coaster - delamination
    Printed Fragment Coaster – delamination

    The chipboard is Quickboard from Makerstock, which is basically recycled-fiber chipboard with the advantage of being through-dyed in cheerful colors. It’s described as “2 mm-thick, three-layered board” and it looks like the core delaminated from the bottom layer.

    Seeing as how it’s near the end of Sweaty Mug season, I smeared Elmer’s Glue Stick PVA adhesive over the fragment, stuck it back in place, and declared victory.

    While doing that, however, I noticed a pinhole:

    Printed Fragment Coaster - delamination detail
    Printed Fragment Coaster – delamination detail

    You may recall the outline came from hand-tracing a fragment of smashed glass in GIMP to get a path, then 3D printing a base to hold it:

    Printed Coaster - Set C - oblique
    Printed Coaster – Set C – oblique

    Going back to the original GIMP tracing (storage being cheap, never delete anything), I missed a pixel:

    Printed Fragment Set C - GIMP selection - errant pixel
    Printed Fragment Set C – GIMP selection – errant pixel

    Surely you can see it, particularly because you know exactly where it is. Right?

    The (degenerate) path around that pixel becomes a tiny vector in LightBurn:

    Printed Fragment Coaster - Set C - orphan vector
    Printed Fragment Coaster – Set C – orphan vector

    It’s easier to see there. Right?

    Whereupon LightBurn dutifully punched a pinhole through the chipboard, because that’s what I asked it to do. It also punched that pinhole into the metallized paper reflector under the smashed glass fragment, but I didn’t notice it then, either.

    Shrinking the GIMP selection by one pixel width, then growing it by one pixel would eliminate single-pixel selections: just another item on the to-do list while tracing fragments.

    Ya learn something new every day around here …

  • Another Snowflake Coaster Reaches EOL

    Another Snowflake Coaster Reaches EOL

    Apparently a year in the bathroom under a cup with constant moisture is enough to ruin untreated wood inlaid in an acrylic coaster:

    Mildew on wood snowflake coaster
    Mildew on wood snowflake coaster

    A small 3D printed chipboard fragment coaster now enters service:

    Printed Fragment Coaster - small
    Printed Fragment Coaster – small

    I recently ran into an interesting chipboard failure suggesting this one won’t last forever, so the clock is ticking.

    About which, more later.

  • PolyDryer Humidity: September

    PolyDryer Humidity: September

    After six months to see how much moisture entered from the 50%RH (±5%RH) basement air:

    2026-09-07
    Filament%RHWeight – gWt gain – gGain %
    PETG White2656.26.212.4%Gel
    PETG Black2857.37.314.6%Gel
    PETG Orange3454.14.18.2%Alumina
    PETG Clear3754.44.48.8%Alumina
    PETG-CF Blue3854.04.08.0%Alumina
    PETG-CF Gray3456.46.412.8%Gel
    PETG-CF Black2556.36.312.6%Gel
    PETG Blue3855.95.911.8%Alumina
    TPU Clear3456.36.312.6%Alumina
    TPU Black3255.25.210.4%Alumina

    Sorted by relative humidity:

    PETG-CF Black2556.36.312.6%Gel
    PETG White2656.26.212.4%Gel
    PETG Black2857.37.314.6%Gel
    TPU Black3255.25.210.4%Alumina
    PETG Orange3454.14.18.2%Alumina
    PETG-CF Gray3456.46.412.8%Gel
    TPU Clear3456.36.312.6%Alumina
    PETG Clear3754.44.48.8%Alumina
    PETG-CF Blue3854.04.08.0%Alumina
    PETG Blue3855.95.911.8%Alumina

    Fairly obviously, there is no correlation between the humidity level and the amount of adsorbed water.

    The silica gel beads were rather dark, not that that means much:

    Silica Gel beads - 2026-09-07
    Silica Gel beads – 2026-09-07

    All the boxes now contain 50 g of alumina beads.

  • Yellowjacket Nest

    Yellowjacket Nest

    Although I’d sealed the cracks around the front door after the previous Yellowjacket encounter, a cloud of Yellowjackets revealed their queen had set up housekeeping between two plants in front of our house. I donned my beekeeper suit, sprayed the obvious entrances with wasp killer, then repeated the dose over the next several days until, as Khruschev apparently didn’t say, the survivors envied the dead.

    The nest was about a foot in diameter, with the top slightly above ground level and bonded into the leaf / mulch layer:

    Yellowjacket wasp nest - top overview
    Yellowjacket wasp nest – top overview

    It had two active layers below the top (positioned upside-down here):

    Yellowjacket wasp nest - side view
    Yellowjacket wasp nest – side view

    The bottom view gives a better idea of its extent:

    Yellowjacket wasp nest - bottom overview
    Yellowjacket wasp nest – bottom overview

    I know nothing of wasp nest building, but if they’re similar to honeybees, then the much larger cells in the disk were intended to raise overwintering queens to start new nests next spring:

    Yellowjacket wasp nest - new cell structure
    Yellowjacket wasp nest – new cell structure

    The longer capped cells sticking out beyond the others may raise the few drones required to mate with queens from other nests:

    Yellowjacket wasp nest - capped cells
    Yellowjacket wasp nest – capped cells

    That’s a fly over on the left; the scavengers wasted no time getting in there for the (perhaps still poisonous) goodies.

    My wasp identification skillz are weak, but this looks like an American Yellowjacket:

    Yellowjacket wasp nest - wasp dorsal view
    Yellowjacket wasp nest – wasp dorsal view

    The definitive test requires going face-to-face with a wasp to find the three dots on a German Yellowjacket.

    However, all yellowjackets wear yellow-and-black livery and that’s enough ID for me!

  • Jumping Spider

    Jumping Spider

    If Jumping Spiders like this one were much larger than 5 mm, they’d be terrifying:

    Jumping Spider
    Jumping Spider

    It appeared atop a trash can and, as with all Jumping Spiders, it’s here or there without being anywhere in between.

    I eased the trash bag inside, gently lowered the lid, bade it happy hunting, and we parted on good terms.

  • E-Bike Brake Sensor Bench Check

    E-Bike Brake Sensor Bench Check

    A pair of brake sensors with LED indicators arrived and should improve the situation on Mary’s bike.

    The connector pinout, as seen looking into the jack on the controller side of the cable:

    Bafang Brake Sensor pinout
    Bafang Brake Sensor pinout

    Of course, one cannot depend on color codes, but now we know it uses a 5 V supply. Some rummaging produced a suitable (“Julet”) connector, a cutoff USB cable, and a USB power supply:

    Tour Easy LED brake sensor - bench test harness
    Tour Easy LED brake sensor – bench test harness

    You’ll note the sensor’s signal wire is blue, not white, but red = 5 VDC and black = common on both sides of the splice. This is not to be sniffed at.

    With the disk magnet (supplied with the sensors) oriented edgewise to the sensor, so the magnetic field is largely cancelled, the maximum separation allowing the sensor to remain On is about 7 mm:

    Tour Easy LED brake sensor - edge - max ON
    Tour Easy LED brake sensor – edge – max ON

    The minimum distance allowing it to be Off is 8 mm:

    Tour Easy LED brake sensor - edge - min OFF
    Tour Easy LED brake sensor – edge – min OFF

    Orienting the disk face-on to the sensor increases the distances, because the magnetic field is not cancelled out in that direction. Similarly, positioning the magnet either above or below the plane of the sensor changes the results.

    The maximum On distance is now 20 mm:

    Tour Easy LED brake sensor - side - max ON
    Tour Easy LED brake sensor – side – max ON

    The minimum Off distance is 22 mm:

    Tour Easy LED brake sensor - side - min OFF
    Tour Easy LED brake sensor – side – min OFF

    The other magnet has a similar field strength and the other sensor responds at nearly the same distances, so they’re reasonably matched.

    The LEDs are, however, not well matched: one sensor is much brighter than the other. I only have one connector, so I cannot show both in the same picture. These pictures have the same exposure (1/120 s and f/1.7), with the top sensor appearing in the previous pictures:

    E-bike Brake Sensors - LED Brightness comparison
    E-bike Brake Sensors – LED Brightness comparison

    The red LEDs show a similar difference. I’m certain this doesn’t rise to the level of a warranty claim, because, hey, maybe the brighter one should be dimmer.

    Now, to fit them on Mary’s bike …