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: Software

General-purpose computers doing something specific

  • Worm Bin Vent Covers

    Worm Bin Vent Covers

    The current iteration of our Tumbleweed Can-O-Worms suffers from leakage down the legs:

    Worm Bin - leg leakage
    Worm Bin – leg leakage

    Perhaps surprisingly, the whole process is odorless. This is in the basement where ugly doesn’t count for much.

    The leakage comes through the air vent holes at the top of each leg socket:

    Worm Bin Vent Cover - vent
    Worm Bin Vent Cover – vent

    Unsurprisingly, the “worm tea” (it ain’t water!) dripping from the bottom of the compost tray goes directly through the vent holes and down the leg. It’s not clear to me what they expected.

    A simple 3D printed black TPU cap atop the leg socket should prevent most of the leakage:

    Worm Bin Vent Cover - installed
    Worm Bin Vent Cover – installed

    The odd pattern comes from Concentric infill around the notch, even though Concentric infill seems better suited to round things and fat extrusion threads with a 0.8 mm nozzle than straight lines. The weird stuff on the vertical side is a reflection of the basement and phone flash from the smooth TPU layer edges.

    The tray with the worms and compost sits atop the strut between the socket and the body, with the cap allowing room for the screen keeping the worms out of the sump.

    Ribs on the underside of the cap hold it above the leg socket to let the air through:

    Worm Bin Vent Covers - solid model
    Worm Bin Vent Covers – solid model

    Although five caps fit the MK4’s platform, I printed one or two at a time while tweaking improving the design:

    Worm Bin Vent Covers - PrusaSlicer preview
    Worm Bin Vent Covers – PrusaSlicer preview

    This design is for the original Can-O-Worms shown in the second picture and may not quite fit the new version. We’ll know more when we empty the bottom tray.

    The OpenSCAD source code as a GitHub Gist:

    // Worm Bin Leg Vent Cover
    // Ed Nisley – KE4ZNU
    // 2026-10-16
    include <BOSL2/std.scad>
    /* [Hidden] */
    ID = 0;
    OD = 1;
    LENGTH = 2;
    HoleWindage = 0.2;
    Protrusion = 0.01;
    NumSides = 8*2*3;
    $fn=NumSides;
    LayerHeight = 0.4; // print with 0.8 mm nozzle
    LayerWidth = 0.9;
    WallThick = 1.5*LayerWidth;
    VentOD = 62.0; // at bottom of cover
    VentTopClear = 9.0; // to next layer bottom
    VentSideClear = 11.0; // to bin side
    VentStrutWidth = 3.0;
    CoverHeight = 15.0;
    CoverOD = VentOD + 2*VentSideClear – 2*WallThick;
    NumRibs = 6;
    RibHeight = VentTopClear – WallThick – 2.0;
    RibThick = 2*WallThick;
    //—–
    // Build things
    difference() {
    union() {
    cyl(WallThick,d=CoverOD,circum=true,anchor=BOTTOM) position(TOP) {
    tube(CoverHeight – WallThick,od=CoverOD,wall=WallThick,circum=true,
    anchor=BOTTOM,spin=180/NumSides);
    for (i=[0:NumRibs–1])
    rotate(i*(360/NumRibs) + 180/NumRibs)
    right(CoverOD/3 – RibThick/2)
    cube([CoverOD/3,RibThick,RibHeight],anchor=BOTTOM);
    }
    up(WallThick)
    right(CoverOD/2 – WallThick)
    cube([VentSideClear,VentStrutWidth + 2*WallThick,RibHeight],anchor=BOTTOM+RIGHT);
    right(CoverOD/2 – WallThick + Protrusion)
    cube([VentSideClear – WallThick,VentStrutWidth + 2*WallThick,CoverHeight],anchor=BOTTOM+RIGHT);
    }
    down(Protrusion)
    right(CoverOD/2 – VentSideClear)
    cube([CoverOD,VentStrutWidth,2*CoverHeight],anchor=BOTTOM+LEFT);
    }

  • HQ Sixteen: Improved Anchor

    HQ Sixteen: Improved Anchor

    The original anchor / weight keeping the HQ Sixteen from rolling away suffered a disastrous fall, so I conjured a much better-looking replacement from the vasty digital deep:

    HQ Sixteen - improved anchor
    HQ Sixteen – improved anchor

    The handle and fancy nut came from the deceased pepper mill, sitting on laser-cut acrylic in a 3D printed base, with a drawer liner disk peeking out from underneath.

    The orange disk in the solid model represents the steel slug harvested from the old anchor:

    HQ Sixteen Anchor - solid model - Show view
    HQ Sixteen Anchor – solid model – Show view

    A ring of hot-melt glue under the weight keeps it from rattling around in there, with the snug-fitting central post encouraging good positioning. I made the acrylic lid sit flush with the top of the base by the simple expedient of running another ring of glue around it, plunking the base + weight atop it on a flat surface, then taking a deep breath while the glue solidified. The nut & screw thus compress a solid stack of acrylic + glue + steel + glue + PETG-CF, rather than just parts flying in formation.

    The OpenSCAD source code also produces a pair of outlines for laser-cutting the adhesive sheet and acrylic, suitable for export to an SVG file:

    HQ Sixteen Anchor - solid model - cuts
    HQ Sixteen Anchor – solid model – cuts

    They’re offset inward by amounts appropriate for my CO₂ laser:

    if (Layout == "Cuts") {
      left(BaseOD/2 + Gap)
        offset(r=-1.0)
          circle(d=BaseOD);
      right(Cap[OD]/2 + Gap)
        offset(r=-0.2/2)
          projection()
            tube(1.0,id=Cap[ID],od=Cap[OD],anchor=BOTTOM);
    }
    

    It might be prudent to apply those offsets to the original outlines in LightBurn or whatever you use for lasering.

    The OpenSCAD source code as a GitHub Gist:

    // Anchor block for HQ Sixteen
    // Ed Nisley – KE4ZNU
    // 2026-09-29
    include <BOSL2/std.scad>
    Layout = "Show"; // [Show,Build,Cuts]
    /* [Hidden] */
    ID = 0;
    OD = 1;
    LENGTH = 2;
    Gap = 10.0/2; // build platform minimum spacing
    HoleWindage = 0.2;
    Protrusion = 0.1;
    NumSides = 8*3*2*4;
    $fn=NumSides;
    // Sizes
    Screw = [5.5,25.5,5.0]; // 10-24 screw + washer holding it together
    Weight = [11.0,80.0,11.5]; // stamped steel slug
    Cap = [26.0,Weight[OD],5.5]; // acrylic disk with handle hole
    BaseFloor = 10.0;
    BaseOD = 90.0; // printed anchor
    Spacing = 25.0; // Show view separation
    //———-
    // Model things
    module Housing() {
    tube(Screw[LENGTH],id=Screw[OD],od=BaseOD,anchor=BOTTOM) position(TOP) {
    tube(Weight[LENGTH],id=Screw[ID],od=Weight[ID],anchor=BOTTOM); // weight bushing
    tube(BaseFloor – Screw[LENGTH],id=Screw[ID],od=BaseOD,anchor=BOTTOM) position(TOP)
    tube(Cap[LENGTH] + Weight[LENGTH],id=Cap[OD],od=BaseOD,anchor=BOTTOM);
    }
    }
    //———-
    // Build things
    if (Layout == "Show") {
    Housing();
    color("Orange",0.7)
    up(BaseFloor + Spacing)
    tube(Weight[LENGTH],id=Weight[ID],od=Weight[OD],anchor=BOTTOM);
    color("Gray",0.8)
    up(BaseFloor + 2*Weight[LENGTH] + Spacing)
    tube(Cap[LENGTH],id=Cap[ID],od=Cap[OD],anchor=BOTTOM);
    }
    if (Layout == "Cuts") {
    left(BaseOD/2 + Gap)
    offset(r=-1.0)
    circle(d=BaseOD);
    right(Cap[OD]/2 + Gap)
    offset(r=0.2/2)
    projection()
    tube(1.0,id=Cap[ID],od=Cap[OD],anchor=BOTTOM);
    }
    if (Layout == "Build") {
    Housing();
    }

  • HQ Sixteen: Improved Fabric Rod Bushings

    HQ Sixteen: Improved Fabric Rod Bushings

    Descending from the previous bearings / sleeves / bushings, I added a rib to hold them in place as the rod slides back and forth while fiddling with fabric:

    HQ Sixteen - Rod Bushing - rib retainer - solid model - build view
    HQ Sixteen – Rod Bushing – rib retainer – solid model – build view

    An idealized serving suggestion:

    HQ Sixteen - Rod Bushing - rib retainer - solid model - show view
    HQ Sixteen – Rod Bushing – rib retainer – solid model – show view

    Which might count as the “better design” I expected it would need.

    They’re still almost invisible in use:

    HQ Sixteen - Rod Bushing - rib retainer
    HQ Sixteen – Rod Bushing – rib retainer

    Which is as it should be: inconspicuous, no more black dust, and E-Z rotation.

    The modified OpenSCAD source code is added to the original GitHub Gist:

    // Bushing for HQ Sixteen table rods
    // Ed Nisley – KE4ZNU
    // 2026-02-20
    // 2026-09-29 add retaining rib
    include <BOSL2/std.scad>
    Layout = "Show"; // [Show,Build]
    /* [Hidden] */
    ID = 0;
    OD = 1;
    LENGTH = 2;
    HoleWindage = 0.2;
    Protrusion = 0.1;
    NumSides = 8*3*2*4;
    $fn=NumSides;
    Rod = [25.0,28.7,100.0]; // very short rod
    Sleeve = [Rod[OD] + 0.3,31.2 – 0.2,9.0]; // LENGTH = overall
    Rim = [Sleeve[ID],Sleeve[OD] + 6.0,0.6];
    LockRing = [Sleeve[ID],Sleeve[OD] + 2*(1.0),4.0]; // locks sleeve on plate
    IdlerLength = 15.0; // far right end of rods
    NumSlots = 2*4;
    Kerf = 1.0;
    Gap = 5.0;
    module Bushing(oal,lk=false) {
    difference() {
    union() {
    tube(oal,id=Sleeve[ID],od=Sleeve[OD],anchor=BOTTOM);
    tube(Rim[LENGTH],id=Rim[ID],od=Rim[OD],anchor=BOTTOM);
    if (lk)
    up(oal)
    tube(LockRing[LENGTH],id=LockRing[ID],od=LockRing[OD],chamfer=LockRing[LENGTH]/3,anchor=TOP);
    }
    for (a=[0:NumSlots-1])
    zrot(a*360/NumSlots)
    up(oal/4 + Rim[LENGTH])
    right(Sleeve[ID]/2)
    cuboid([Sleeve[OD],Kerf,oal],anchor=BOTTOM);
    }
    }
    //—–
    // Build things
    if (Layout == "Show") {
    color("Gray",0.5)
    xcyl(Rod[LENGTH],d=Rod[OD]);
    right(Rod[LENGTH]/3)
    zrot(180) yrot(90)
    Bushing(Sleeve[LENGTH]);
    left(Rod[LENGTH]/3)
    yrot(90)
    Bushing(IdlerLength,lk=true);
    }
    if (Layout == "Build") {
    right(Rim[OD]/2 + Gap/2)
    Bushing(Sleeve[LENGTH]);
    left(Rim[OD]/2 + Gap/2)
    Bushing(IdlerLength,lk=true);
    }
    // Bearing sleeve for HQ Sixteen table rods
    // Ed Nisley – KE4ZNU
    // 2026-02-20
    include <BOSL2/std.scad>
    Layout = "Show"; // [Show,Build]
    /* [Hidden] */
    ID = 0;
    OD = 1;
    LENGTH = 2;
    HoleWindage = 0.2;
    Protrusion = 0.1;
    NumSides = 8*3*2*4;
    $fn=NumSides;
    Rod = [25.0,28.7,100.0]; // very short rod
    Sleeve = [Rod[OD] + 0.3,31.2 – 0.2,9.0]; // LENGTH = overall
    Rim = [Sleeve[ID],Sleeve[OD] + 6.0,0.6];
    IdlerLength = 15.0;
    NumSlots = 2*4;
    Kerf = 1.0;
    Gap = 5.0;
    module Bearing(oal) {
    difference() {
    union() {
    tube(oal,id=Sleeve[ID],od=Sleeve[OD],anchor=BOTTOM);
    tube(Rim[LENGTH],id=Rim[ID],od=Rim[OD],anchor=BOTTOM);
    }
    for (a=[0:NumSlots-1])
    zrot(a*360/NumSlots)
    up(oal/4 + Rim[LENGTH])
    right(Sleeve[ID]/2)
    cuboid([Sleeve[OD],Kerf,oal],anchor=BOTTOM);
    }
    }
    //—–
    // Build things
    if (Layout == "Show") {
    color("Gray",0.5)
    xcyl(Rod[LENGTH],d=Rod[OD]);
    right(Rod[LENGTH]/3)
    yrot(90)
    Bearing(Sleeve[LENGTH]);
    left(Rod[LENGTH]/3)
    yrot(90)
    Bearing(IdlerLength);
    }
    if (Layout == "Build") {
    right(Rim[OD]/2 + Gap/2)
    Bearing(Sleeve[LENGTH]);
    left(Rim[OD]/2 + Gap/2)
    Bearing(IdlerLength);
    }
  • Knitted Spider: Eyemaxxing

    Knitted Spider: Eyemaxxing

    A 3D printed spider with a knitted texture seemed a sufficient oxymoron to justify its existence:

    Knitted Spider - black eyes
    Knitted Spider – black eyes

    But all-black looked rather somber, even for an All Hallow’s Eve decoration, so I used PrusaSlicer’s Multi-Material Painting to print the eyes in retina-burn orange:

    Knitted Spider - orange eyes - wipe tower
    Knitted Spider – orange eyes – wipe tower

    The chunky wipe tower shows the cost of switching filaments for a quartet of little eyes. The new Prusa INDX extruder design reduces that waste, but I’m not going there.

    You can see the block of painted-on support under the palps, which worked better than overenthusiastic automatic support generation.

    The consensus suggested the spider suffered from insufficient eye, so I upleveled it to maximum spider spec:

    Knitted Spider - 8 eyes - on platform
    Knitted Spider – 8 eyes – on platform

    Which looks like evolution in action:

    Knitted Spider - iteration
    Knitted Spider – iteration

    The additional eyes came from a trivial OpenSCAD / BOSL2 sphere:

    include <BOSL2/std.scad>
    spheroid(d=5.0,style="icosa");
    

    Which is both small and large enough to have a useful number of facets:

    Knitted Spider - 5mm icosa sphere eye model
    Knitted Spider – 5mm icosa sphere eye model

    Those facets will come in handy for Multi-Material Painting.

    Adding the sphere to the spider model turned out to be trickier than I imagined, because PrusaSlicer requires object to sit flat on the platform, but merging the sphere and spider models got it done:

    Knitted Spider - merged models
    Knitted Spider – merged models

    Then you can use the Move tool to haul the sphere into place:

    Knitted Spider - eye positioning
    Knitted Spider – eye positioning

    Use the Scale tool to reduce it to a suitable size.

    With the eye in place, copy-n-paste creates a duplicate Merged sphere at the same coordinates, which you chivvy into its proper spot. Repeat as needed for more eyes!

    The sphere facets are far below the 0.4 mm nozzle’s resolution, but they simplify painting the eye with “Smart Fill” angle settings:

    Knitted Spider - 8 eyes - slicer material painting
    Knitted Spider – 8 eyes – slicer material painting

    I had initially thought to just drop separate spheres in place and assign them to the orange extruder, but the slicer (quite properly) treats them as separate objects and creates balls sitting in sockets.

    Instead, the eyes must become part of the spider’s shape, have their exterior surfaces painted, then get sliced. In order to do that, I exported the 8-eyed spider as a new STL file and imported it back for painting & slicing:

    Knitted Spider - 8 eyes - slicer model
    Knitted Spider – 8 eyes – slicer model

    The original single-color spider prints in an hour and adding any number of eyes doubles the time, so those MMU3 tool changes are expensive. Although the printer is reliable, the auto-retract spools I set up sometimes retract the filament beyond the feed gear inside the MMU3, which the firmware detects and calls for manual intervention. It’s best to be puttering in the basement while the printer buzzes away.

  • Dog Paw Coaster

    Dog Paw Coaster

    Start with a picture of a dog paw:

    Dog Paw Coaster - starting picture
    Dog Paw Coaster – starting picture

    Rescale the paw to about 100 mm vertically to properly fit a normal-size glass / tumbler / mug. This may be considerably larger than life, but dog owners always want more dog, so it’ll work.

    Generate an outline mask in GIMP:

    Dog Paw Coaster - paw mask
    Dog Paw Coaster – paw mask

    Generate another mask for the pads & toenails:

    Dog Paw Coaster - pad mask
    Dog Paw Coaster – pad mask

    Convert those into paths, save them as SVG files, and hand them to OpenSCAD:

    include <BOSL2/std.scad>
    
    /* [Hidden] */
    
    PadThick = 1.2;
    BaseThick = 2.0;
    
    RimHeight = 0.4;
    RimWidth = 0.8;
    RimOffset = 1.0;
    
    Clearance = 0.1;    // embiggen pad recesses
    
    OutlineFN = "Dog Paw - Outline.svg";
    PadFN = "Dog Paw - Pads.svg";
    
    union() {
    
    
      linear_extrude(h=BaseThick)
        import(OutlineFN);
    
      color("Green")
        up(BaseThick)
          linear_extrude(h=PadThick)
            difference() {
              import(OutlineFN);
              offset(r=Clearance)
                import(PadFN);
            }
    
      
    }
    

    Which will get you a solid model like this:

    Dog Paw Coaster - OpenSCAD model
    Dog Paw Coaster – OpenSCAD model

    Should you want decorative raised rims around the perimeter and pads:

    Dog Paw Coaster - raised rim - OpenSCAD model
    Dog Paw Coaster – raised rim – OpenSCAD model

    Then turn this on:

    if (false)
      color("Red")
        up(BaseThick + PadThick)
          linear_extrude(h=RimHeight) {
            difference() {
              offset(r=RimOffset + RimWidth)
                import(PadFN);
              offset(r=RimWidth)
                import(PadFN);
            }
            difference() {
              offset(r=-RimOffset)
                import(OutlineFN);
              offset(r=-(RimOffset + RimWidth))
                import(OutlineFN);
            }
          }
    

    Run the solid model through PrusaSlicer, send it to the MK4, and, while the printer is buzzing away, run the pads through an online nesting program to see how well that works:

    Dog Paw Coaster - Pads nesting - LightBurn layout
    Dog Paw Coaster – Pads nesting – LightBurn layout

    While nesting didn’t save much material, it might come in handy for something more intricate and now I’ll be able to find it again.

    Then get busy:

    • Stick adhesive sheet to the chipboard
    • Mirror the pads to cut adhesive side up
    • Cut the pads, rescue a toenail from the chip tray
    • Import the paw outline SVG
    • Offset 0.75 mm inward
    • Stick adhesive sheet on the cork
    • Cut paw outline (adhesive up, but not mirrored!)
    • Peel & stick

    Which turned out pretty good:

    Dog Paw Coaster - assembled
    Dog Paw Coaster – assembled

    I used Concentric infill on the top to resemble the fur pattern, but it came out way too subtle.

    The owner liked it, though, which made it all worthwhile.

  • CUPS 2.4.19 vs. Printing

    After a rather tedious morning devoted to figuring out why printing had suddenly stopped working, it seems there’s something badly wrong with the most recent CUPS update.

    The symptoms included:

    • Wrong sheet orientation for multi-page output regardless of the Landscape or Portrait setting
    • No output at all, generally with a CUPS error message

    The error messages were utterly inscrutable:

    • “missing required flags”
    • “cfFilterChain: pdftopdf (PID 8189) stopped with status 1”
    • “temp file (object 3 0, offset 11462): dictionary has duplicated key /x12; last occurrence overrides earlier ones”

    Downgrading two packages restored the status quo ante:

    • libcupsfilters 2.2.1-2 → 2.1.1-4
    • cups 2.4.19-1 → 2.4.16-2

    Perhaps cups need not be reverted, but I’m loathe to fiddle around with it now that printing works again.

    Those are now frozen in /etc/pacman.conf:

    IgnorePkg = cups libcupsfilters
    
    

    The least-awful way to downgrade / revert packages seems to be with manjaro-downgrade. You can, of course, do it on hard mode with pacman or pamac, but perusing a list of what’s in the update cache helped figure out what just changed.

    And there they will sit until the next update rolls through.

  • Huion H610Pro Tablet vs. Digimend vs. DKMS

    Huion H610Pro Tablet vs. Digimend vs. DKMS

    A month or two ago the Huion H610Pro tablet’s buttons stopped working with the input-remapper macros I set up to do useful things. Considerable searching showed that the Digimend kernel driver project previously handling the buttons went inertial two years ago and, apparently, no longer worked with contemporary kernels. Further searching suggested old Huion tablets, which mine certainly is, should be handled by the native kernel / X drivers, so I uninstalled Digimend.

    Which produced a persistent error message from the DKMS machinery telling me something awful was happening with the now-missing Digimend.

    An Arch Linux BBS thread suggested manually removing various detritus left behind during successive kernel updates in places like /usr/lib/modules and /var/lib/dkms. Given that my desktop box runs the 6.18 kernel, I felt reasonably confident in removing the 5* kernel directories and anything mentioning digimend from those locations.

    After the box started up the next morning, all the tablet buttons once again worked the way they use to.

    The nice thing about Free Software is having access to all the pieces when something breaks …