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

  • Miniature Planetary Gear Bearings

    Miniature Planetary Gear Bearings

    Because it’s easy to scale solid models:

    Small Planetary Gear Bearings - PETG PETG-CF
    Small Planetary Gear Bearings – PETG PETG-CF

    The small bearings are 25 mm OD, with correspondingly small clearances between their moving parts, but they all spun easily after a bit of breaking in.

    As with their larger cousins, the orange PETG bearing has the most axial play and worked just fine right off the platform. The gray PETG-CF bearing was jammed and required concerted effort to get the gears rolling, but now has essentially no axial play while turning easily. The snappy-looking orange and black bearing has very little play and feels the best of the three.

    The single-material bearings take about 20 minutes to print, while the mixed material one requires 80 minutes due to the extruder purging and nozzle clearing. The larger mixed material bearing took more than three hours, but time doesn’t scale as the cube of the size because changing materials runs at a constant time:

    Small Planetary Gear Bearings - PETG PETG-CF with wipe towers
    Small Planetary Gear Bearings – PETG PETG-CF with wipe towers

    The smaller mixed gear produced the smaller wipe tower on the right, but changing materials remains an expensive process. Of course, if you were doing this in production, you’d make a couple dozen of the little things in one job: the machine would spend most of its time squirting out planetary gear bearings with the same number of material changes building the same size wipe tower.

    They’re slightly too small for my fingers and surely pose a choking hazard to children, but they’re definitely cute.

  • Revised Measuring Spoon Drainer

    Revised Measuring Spoon Drainer

    A small tweak to the venerable spoon drainer adds a configurable cutout adapting it to a slightly different dish drainer rack:

    Measuring Spoon Drainer - solid model
    Measuring Spoon Drainer – solid model

    Which lets it snuggle into the corner:

    Measuring spoon drainer - installed
    Measuring spoon drainer – installed

    Both the old and new racks had coated steel loops stuck into rubberoid feet perfectly suited to collect water and eventually rust the loops. Given a new rack, I figured potting the feet in JB PlasticBonder urethane adhesive would help forestall the rust:

    Rubbermaid dish drainer - foot potting
    Rubbermaid dish drainer – foot potting

    I wish it were white, rather than black, but the only other color choice is tan and I can’t wish nearly that hard.

    Along those lines, however, the gray JB Weld epoxy coating on the cheese slicer and the smaller repairs on the big knife are doing fine after years of use. JB Weld is good stuff!

  • DVD Coasters: Stress Cracking

    DVD Coasters: Stress Cracking

    A bit less than a year ago I engraved Guilloche patterns on a stack of DVDs, stuck foam on their data sides, and defined the result to be coasters:

    Laser cut CDs - Foam vs MDF-cork backing - detail
    Laser cut CDs – Foam vs MDF-cork backing – detail

    Perhaps unsurprisingly, those grooves turned out to be excellent stress raisers, to the extent that the two most-used coasters (we’re not talking heavy use) have developed cracks:

    Laser-engraved DVD A - stress cracks
    Laser-engraved DVD A – stress cracks

    The parallel lines are part of the logo / pattern / design printed on the label side of the disc, which seems to have wrinkled after being glued to the foam layer. The cracks radiate outward from the laser-scarred zone around the hub.

    The other one is worse:

    Laser-engraved DVD B - stress cracks
    Laser-engraved DVD B – stress cracks

    None of the discs glued to rigid backing plates show anything more than minor cracks, so I think a combination of stress raising and slight flexing is really bad for cheap coaster-like objects.

    No great loss, easily outweighed by knowing what not to do next time …

  • Anker A1215 PowerCore 13000 Power Banks: Five Years

    Anker A1215 PowerCore 13000 Power Banks: Five Years

    After five years of powering the action cameras on our Tour Easy recumbents, the pair of Anker A1215 PowerCore 13000 USB power banks have about 8 A·hr of capacity with a 2 A load after a full charge:

    Anker PowerCore 13000 - 20204-07-26
    Anker PowerCore 13000 – 20204-07-26

    It seems I did not test them on arrival, so I have no idea what their original capacity might have been, but I’m certain it wasn’t the 13 A·hr implied by their name.

    The sawtooth voltage output looks like the internal controller picks a constant boost (or buck) ratio based on the battery voltage, then adjusts it when the output voltage falls below the lower limit. You can imagine it desperately boosting the ratio as the battery voltage falls off a cliff near the end of the curve.

    I have no idea why the two packs behave so differently, although the voltages are certainly within ordinary USB limits.

    They’ll continue powering the camera on my bike for a while, after which I’m sure they’ll come in handy for something …

  • Please Close The Gate Signs: One Year

    Please Close The Gate Signs: One Year

    They still look pretty good after a year:

    Please Close The Gate - weathered acrylic - 2024-07-20
    Please Close The Gate – weathered acrylic – 2024-07-20

    Which is to say: the orange acrylic hasn’t faded, the black paint’s still in place, and the gates seem to stay closed.

    One might quibble about the missing wire snippet on the lower left corner, but on the whole it doesn’t get much better than that …

  • Laser Test Paper: Plant Label Testing

    Laser Test Paper: Plant Label Testing

    After a month outdoors, the (failed) flexible strip labels show signs of wear:

    Laser test paper - 1 month weathering
    Laser test paper – 1 month weathering

    The upper one has a coating of clear rattlecan paint and looks much the better for it. The lower one is bare, but also suffered greatly from being folded and tucked through itself, so it started in worse condition.

    Perhaps the paper will work better when stuck to metal plant label stakes, although I suspect the adhesive sheet will fail first:

    Laser test paper - small plant labels
    Laser test paper – small plant labels

    Those are random names; Mary tells me the proper label format has the Latin nomenclature on the first line.

    They’re now out on the patio for observation.

    For whatever it’s worth, my fascination with this paper boils down to “it’s cheaper than Trolase” for applications not requiring archival quality and duration. If it lasts Long Enough, that’ll be Good Enough.

  • COVID Buffer Extraction Tube vs. Acrylic Solvent Adhesive

    COVID Buffer Extraction Tube vs. Acrylic Solvent Adhesive

    This seemed like a good idea for dispensing small drops of acrylic solvent while gluing spiders together:

    COVID test Buffer Extraction Tube - adhesive hack
    COVID test Buffer Extraction Tube – adhesive hack

    It’s the Buffer Extraction Tube from a COVID-19 rapid test kit with a short brass tube jammed in its dropper tip. The longer brass tube let me suck that dose of solvent into the tube without any of the hassle required to pour the liquid from a big can into a little tube.

    Tell me you didn’t save those things because you thought they didn’t look like they might come in handy for something.

    Well, that turned out to be a Bad Idea™, because whatever plastic that tube is made out of cracks when exposed to the hellish mixture in SCIGRIP #3 solvent adhesive. The tube didn’t dissolve or melt, it just cracked when you (well, I) squeezed the sides.

    My Box o’ Test Kits has a few other types of tubes, but I used a syringe from the inkjet refilling era and that worked OK.