Wear a Circuit Workshop

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Participants with their finished circuit patches at Sunday’s Wear-A-Circuit workshop.

I make knitted circuit boards on my knitting machine. Sunday I brought in a stack of 3″ x 5″ knitted proto-boards for us to turn into wearable electronics.

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Soldering LEDs and batteries 2016-10-30-16-36-34img_20161030_174439_30604255612_o  colleen-circuit-highres_455653410

 

 

 

 

 

 

 

 

Doug attaches his to a hat

 

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Colleen used the four rows to make a zig zag pattern.

 

 

 

The event  attracted a number of spectators, curious about my original knitted circuit design.

Their discussion encouraged me to look into doing this again, perhaps using more complex, interactive projects.

So if you’re interested in participating, keep an eye out here for updates. And if you have suggestions/feedback on the future of these workshops, do get in touch!

03

11 2016

Fare thee well, Tardis, until we meet again

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I first noticed PS:1 because of the sign on the door – the, “Yes we have a Tardis” message. I was intrigued enough to cross the street, look up and see, yep, there’s a Tardis up there. A freaking Tardis!

‘Clearly, this is the place for me,’ I thought.

Fast forward several years.  PS:1 has changed and grown, getting bigger and better, but sadly, the Tardis, has not weathered (pun intended) the years well. I have been on the roof several times over the years.  Each time I stopped to take a look at the Tardis, noting that maybe with some TLC, it could be restored to its former glory as a beacon for folks who wanted to find a place to be whimsical, playful, and creative.

Over the past year particularly, it became extremely obvious that it was suffering real damage, and if there was going to be any chance of saving it, the time had come to try. At best, I figured we could disassemble and rebuild it, and even possibly use it to hide the new dust collector. Upon investigation, we determined that the wood was rotted through, and that it was a real hazard to everyone and everything on Elston Ave. below.  A bad storm would likely have ripped off large chunks, sending them flying straight into a law suit.

So Ken, Andy, and I, with assistance from Kyle who happened to have a pickup truck with an empty bed, the disassembly and lowered the pieces to the street below. Most were lowered by some rope Andy just happened to have; some pieces we simply chucked overboard (always timed so nobody was anywhere near PS:1). Given how heavy some of the parts were, I’m quite impressed with the folks who got it up there in the first place!

After the large pieces came down, Kyle sent up some garbage bags and we cleaned up the rest, leaving little to indicate that anything had ever been up there. Mike Skilton was on hand to help unload Kyle’s truck and cut the chunks down to dumpster size.  As I write this, a fair number of the pieces are sitting on a pallet on the loading dock, waiting for the dumpster to be emptied so they can be thrown away.

This makes me sad.

The Tardis has been around since very early days. It can be seen on PS:1’s Flickr pool going back to the original space. The Tardis is an emblem of the spirit of the space, and demonstrates what can be done by a group of individuals with a common purpose: to make something awesome that makes others happy. Personally, I think of PS:1 not as a collection of tools and equipment, but of interesting people who want to make and do interesting things – and who can and do come together from time to time to make PS:1 itself better. PS:1 is the place it is because of people helping each other. To anyone who has installed something, volunteered for a committee, fixed equipment, or shared an idea to make the place better for everyone, I say this: you have made PS:1 more than just a random collection of tools. You have made it a community.
I propose that it is time for the community to come together once again to build Tardis 2.0. I whipped up a rough design that would use a steel skeleton clad in weatherproof paneling.  In addition to having its windows lit up, it could enclose a weather station and even a webcam.

 

I believe the PS:1 folks can bring their skills to replace the empty space on the roof with a better, more durable Tardis that will continue to elicit smiles and curiosity from passers-by (I can think of three separate times when people have shown up for the open house because they wanted to know what PS:1 was solely because they saw the Tardis on the roof) and hopefully will see it like I did: as an sign that this small beige building is a great community and space for people to have fun and be creative.


Last chance to see:

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28

10 2016

Wear-A-Circuit Workshop on Sunday

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Circuit Patches are wearable circuit boards made from knitted yarn and wire. I’m doing a workshop Sunday using these. Check it out!

I use a knitting machine to make the patches. Add snap buttons and  attach the circuits to anything you like.

Rapid prototyping for Wearables!

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I made these patches for my workshop this Sunday, 3-5pm. Participants will receive a 3″ x 5.5″ knitted proto-boards in black, pink, or teal. Solder LEDs and a battery on it, and you can add lights to your clothes, just in time for Halloween.

 

Of course, there’s lots of things beyond LEDs you could add– I’m hoping to do workshops for interactive circuits using the knitted protoboards in the future.

I’ve made a number of circuits with this method so far, often in black. For this workshop, we’re adding  fun colors: circuit-board-teal and… pink! I  couldn’t resist adding 10mm gumdrop LEDs to the pink protoboard pictured above.

We’ll have some of those jumbo LEDs for the workshop, but also smaller ones in blue, yellow, red, white. I’ve even got some color-change and flicker LEDs.

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Power is supplied by a hidden battery pack.

If you’d like to participate, please RSVP. Hope to see you Sunday! (Bring a shirt or a hat or a bag so you can add snaps to mount your circuit on it.)

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My new favorite machine: the snap press applies snap buttons without sewing.

27

10 2016

NERP^2 = Hardware: From Concept to Retail && PiAQ: Indoor Air Quality Sensor

PLEASE NOTE: NERP WILL GET UNDER WAY AT EXACTLY 7PM ON MONDAY!

Next Monday at NERP we’ll have a double feature. We’ll hear part 2, of Ste and Nicks’s story of adventure in bringing a successful consumer product to market. Part 1 was about technology, and part 2 is about the _business_ side of bootstrapping HD Retrovision (http://hdretrovision.com). Also on Monday, Dave Conroy will tell us about the PiAQ Open Source Indoor Air Quality Sensor for the Raspberry Pi (http://piaq.io).

hd_retrovision-1

About HD Retrovision:
Nick and Ste have been friends since 1999 and both share a passion for playing the (now retro) video game systems that they grew up on. Since then they’ve both studied Electrical Engineering at University, and are now business partners in a company called HD Retrovision that is dedicated to improving the modern day experience with retro consoles while making it accessible to as many people as possible. In this presentation, Ste and Nick will walk you through the ups, downs, and lessons learned while taking a college project and turning it into a profitable company. This talk will cover how they took the idea for HD Retrovision’s Genesis and SNES cables out of the lab, got it funded, and eventually mass-produced overseas.

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About the PiAQ: As an R&D Engineer for NAR’s Center for REALTOR® Technology & CRT Labs, Dave Conroy investigates emerging technologies, educates NAR members & the public through presentations, webinars, blogs and podcasts, and develops products for use by members. He’s presented to REALTORS® on the national, state and local levels. The PiAQ is an open hardware and software indoor air quality sensor developed by the National Association of REALTORS’ CRT Labs. The goal for this project is to make information about the air people are breathing more accessible.

http://piaq.io/

About NERP:

NERP is not exclusively Raspberry Pi, the small computer and embedded systems interest group at Pumping Station:One in Chicago. NERP meets every other Monday at 7pm at Pumping Station:One, 3519 N. Elston Ave. in Chicago. Find NERP and Pumping Station:One at
http:// www.meetup.com/NERP-Not-Exclusively-Raspberry-Pi/
and
http://pumpingstationone.org/

Doors open at 6:30pm. NERP is free and open to the public. Ed Bennett ed @ kinetics and electronics com Tags: electronics, embedded, NERP, Open Source, raspberry pi, hackerspace, Beagle Bone, Pumping Station One

21

10 2016

NERP Tonite! Google Summer of Code students build BeagleBoard.org projects

Tonight at NERP, Drew Fustini will be sharing highlights from his presentation at Maker Faire New York 2016.

Drew explains How Open Source software and Open Source Hardware intersected in several BeagleBoard based projects done for the Google Summer of Code.  “Google Summer of Code is a global program that offers students stipends to write code for open source projects.”  These students’ projects demonstrate the synergy of devices and the code that makes them what they are.

NERP is not exclusively Raspberry Pi, the small computer and embedded systems interest group at Pumping Station:One in Chicago. NERP meets every other Monday at 7pm at Pumping Station:One, 3519 N. Elston Ave. in Chicago. Find NERP and Pumping Station:One at

www.meetup.com/NERP-Not-Exclusively-Raspberry-Pi/

and

http://pumpingstationone.org/

Doors open at 6:30pm. NERP is free and open to the public. Ed Bennett ed @ kinetics and electronics com Tags: electronics, embedded, NERP, Open Source, raspberry pi, hackerspace, Beagle Bone, Pumping Station One

10

10 2016

My first project, upcoming Doctor Strange movie prop replica

Doctor Strange movie prop replica design pictures

Progress from preview to display of Doctor Strange movie prop replica.

Thanks to everyone who volunteers training and care for the laser cutter. My son and I will have a blast taking these to the opening night.

21

09 2016

Free Workshop: Earring Exposition

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When: Saturday, October 1, 2016, 1:00 pm – 3:00 pm
Where: Arts Area (upstairs) Pumping Station: One 3519 N Elston Chicago, IL 60618

Drop in and make a pair of earrings for yourself or as a gift for someone! This is a very basic form of jewelry assembly, no prior experience is required. Learning this skill may help you financially as the “winter holiday gift season” of various faiths approaches.

Beads and findings will be supplied in nickel-free gold and silver costume metal. Bringing a pair of basic round nose pliers will be helpful if you have your own. Expect total time commitment to be in the range of 10 to 20 minutes. Please limit one project per member so the maximum number of people can participate.

13

09 2016

NERP Tonite! Improving the Retro Gaming Experience

Ste Kulov is Lead Design Engineer at HD Retrovision. Ste (known in NBA Jam as STE) was born and raised in the suburbs of Chicago and spent most of his childhood with his hands glued to a SNES controller. Like so many life-long nerds, Ste went to school for electrical engineering and became an expert at working with circuits. His passion for working on really cool engineering projects is second only to his obsession with video games. Ste conceived the original idea for HD Retrovision in his engineering design class to solve the world’s most pressing problem: allowing gamers to play their old systems on TV’s that don’t have the right inputs. [NERP Note: HD Retrovision cables are analog circuit devices. The HD Retrovision circuit board is molded into the cable.]

PS:One knows Ste for being a really good teacher. We wish he could find time to do more analog and fpga circuit classes (hint, hint).

A vital aspect of manufacturing is testing and quality control. Someone has to do it, and they need test instruments, test fixtures, custom software, and detailed written test requirements and procedures. Ste had to design a turnkey QC system for use by his contract manufacturer. The HD retrovision circuit itself is all analog, but the QC system is FPGA based. At NERP tonite, Ste will explain how you QC a cable on the other side of the world.

NERP is not exclusively Raspberry Pi, the small computer and embedded systems interest group at Pumping Station:One in Chicago. NERP meets every other Monday at 7pm at Pumping Station:One, 3519 N. Elston Ave. in Chicago. Find NERP and Pumping Station:One at

http:// www.meetup.com/NERP-Not-Exclusively-Raspberry-Pi/

and

http://pumpingstationone.org/

Doors open at 6:30pm. NERP is free and open to the public. Ed Bennett ed @ kinetics and electronics com Tags: electronics, embedded, NERP, Open Source, raspberry pi, hackerspace, Beagle Bone, Pumping Station One

12

09 2016

Mandolin Plates on the ShopBot

My name is Ralph, and I’m an amateur luthier and PS:1 “starving hacker”.

I make all kinds of instruments: guitars, ukuleles, bouzoukis, and more, but my favorite thing to build is mandolins.  They are far and away the most difficult instrument that I make, and require a level of craftsmanship not found in the simpler instruments.

There’s only one real downside to building mandolins— the carving.  Mandolin plates are made from 1” thick stock, carved into a very precise dome shape ranging from 3mm thick at the rim up to 6mm thick at the bridge.  Making the plate accurately is the key to getting a good tone from the instrument: too thick and it sounds “dead”, too thin and the top can’t withstand the force of the strings.

To make the plates requires a set of inside and outside templates that show the proper curves (making these templates on the laser cutter was a primary reason I joined PS:1), using carving gouges to get close the the final shape, and then curved planes and scrapers to get the dimensions exact.  There is about 40-50 hours of carving and scraping that go into a set of mandolin plates.  To make things worse, the back plate is made of hard maple, which is VERY difficult to carve.  Even with leather carving gloves, my hands are a mess of blisters and callouses after making a plate.

When I saw the CNC routers at PS:1, I was immediately struck by the idea of using CNC to produce a rough mandolin plate.  Even if I would still need to scrape to get things perfect, the hard carving work (and blisters) would be taken care of by the machine.

Thus began a year-long journey of discovery…

I learned about CAM, and taught myself to use Fusion 360, only to discover that this 3D modeling stuff is HARD.  I managed to turn out some pretty simple models for bridges and headstocks, which I was able to make on the Shapeoko and ShopBot, but every attempt at modeling a mandolin plate failed.

After flailing around for many months, I discovered the Fusion 360 meetup (sponsored by Autodesk and held at PS:1), and everything changed.  With the help of Autodesk’s Michael Aubrey (Fusion evangelist), and PS:1’s resident CAD experts, I improved my skills to the point where I was able to make a reasonable model of the top plate for an A-style mandolin.

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Last weekend, I got to test the model on the ShopBot!  The initial version is in MDF, just to test the model and the machining commands.  Once everything is tweaked, I will do the real thing in Sitka spruce.

Since the plate needs to be machined on both sides, I needed to create a fixture to align everything.  It’s a pretty straightforward plate, with two alignment pegs that match holes drilled into the ShopBot wasteboard.  All of the shaping was done with a 1/2” round-nose bit running at 12000 rpm and a chip load of .35mm.

The inside is machined first, referencing the stock top.  It uses a pretty simple adaptive pocket to remove most of the waste, followed by a spiral with a 1mm overlap to take things to the finished size.

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You’ll note that the pocket is not centered in the picture— my origin was in the wrong place in my model.  I fixed that, and the second attempt came out much better.  There is still a bit of scraping/sanding to remove the machine marks, but that was to be expected.

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After the inside surface was machined, I flipped the workpiece over and re-registered the Z axis to the bottom of the piece.  That way, I know the thickness of the part will be accurate even if my stock thickness is off by a little bit.

Once again an adaptive pocket removed most of the stock, starting with a channel around the rim.

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After the rim was rough-sized, the “hump” was roughed in.

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A second pass of the adaptive pocket got the rim down to 4mm thick, and smoothed the transitions.

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Just as with the inside, the finishing step used a spiral to clean the surface and eliminate the tool marks.  The net result was quite good, and will need only a bit of scraping to finish

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After all was said and done I swapped in a 1/8” straight bit to cut the outer profile and f-holes.

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Cutting off the excess stock left me with a quite nice-looking mandolin top plate!  Total elapsed time (not counting my initial screwup) was about 90 minutes.

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Putting my micrometer to the finished product, the results were better than I expected.  Thickness is accurate within 1mm across the entire profile, with most areas within 0.5mm.  That leaves only a bit of scraping to get things perfect!

Next weekend… the real thing, in sitka spruce.

Many thanks to Michael Aubrey from Autodesk, Ray Doeksen and Andrew Carmadella from PS:1, and all of the Fusion 360 Meetup crew that helped me along the way!  I’m still a modeling rookie, but I’ve come a LONG way with your help!

Ralph Brendler

10

09 2016

A Light Diversion

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In the last days of Radio Shack, I was in a store on Michigan Avenue when I spotted, buried amongst the disassembled shelving units and discarded phone cases, a small red box that turned out to be an Arduino-based soldering project, the 2770158 LED Cube (https://github.com/RadioShackCorp/2770158-LED-Cube). I bought it for something like $5, took it home, and promptly put it on the shelf as a project I’ll ‘get to’ at some point.

The honest truth is that I was somewhat intimidated by the soldering; it’s a 3x3x3 cube of LEDs that are soldered together and the lights were smaller than i was expecting, and looking at some pics of the final result, I resigned myself to likely screwing it up and at best hoping that I might learn something from what I assumed would be a complete failure. So I somehow justified to myself that, in order to not waste my $5, I shouldn’t actually try to make the thing I spent $5 on.

At some point I hit myself with a clue-by-four and realized the stupidity of my situation; accept the possible loss of the $5 and actually try instead of fretting about what-ifs. So I took the kit to PS:1, sat down in the Electronics area, got out the soldering iron, magnifying glass, and went to work. It took a couple of hours, and I was certain, absolutely positively certain, that, even though it looked right, there was no chance that I had actually gotten the leads all wired together correctly, especially the ones in the middle that were extremely hard to reach with the big tip of the soldering iron. Okay, well, only thing left was to actually plug it into the Arduino Uno I had, load up the sample sketch (available in the RS GitHub repo above), and see what happens.

I fired up the Arduino IDE, loaded the sample sketch, hit upload, and all of a sudden all the lights came on as it started through the canned routines. I was initially skeptical, checking every single light to see which one was never lighting up, and all of a sudden it dawned on me that I had actually done it, all the lights actually lit up as part of the demo routine, and HOLY CRAP I MADE A THING AND IT WORKED!!!!1111

And then in my excitement I dropped it, ripping the USB cord from the Arduino, and landed lights-down on the floor. Well, of course I did. Of course I broke it, right? But as I checked the connections, nothing had come loose, there were no broken connections. I plugged the Arduino back in, and sure enough, it happily came back to life and started going through the routine. Whew!

 

So I resolved to make this truly my own; running a demo program that I didn’t write was not ‘finishing the job’. I remembered the QBasic ‘Snake’ program that drew a line bouncing around the screen, hitting the edge and then randomly turning and going off into another direction. Ah, but this is a cube, in threeeee deeeeeeee, so the challenge would be that more interesting, especially as I resolved to sit down and actually try to implement it without any help from the Internet; a three-dimensional matrix of lights, translated into C++.

This is where I remembered a line from Top Gun that went something along the lines of “Our pilots had become dependent on missiles” as a reason for loss of dogfighting ability. (And then I got that Everly Brothers song stuck in my head). Well, writing C++ for years, I had become dependent on the containers provided by the Standard Template Library (map, vector, etc.). While the Arduino is programmed using C++, it’s really a pretty small subset of C++ (which sort-of-kinda-not-really makes sense) and the STL is not available; go ahead and #include <map> all you like, all the compiler’s gonna do is complain. So I knew I’d have to regain some amount of dogfighting capability and do all the array/matrix stuff in pure C. So I decided the best way to keep myself honest and regain some of the skills I think I used to have, I created a C file in Vim (using Emacs always made me angry, straight-up I hate this, whatever this is), wrote the program, saved, compiled and ran straight from the terminal prompt. Again and again and again.

One of the biggest problems was forcing myself to get past the ‘sheesh, this woulda been easy to use <insert some STL thing> here’ and just focus on getting the values in the right cells of the matrix. It took a few hours to get the algorithm right, but pretty soon I had it spitting out numbers that seemed right, but how was I gonna know that it was right?

This is where I decided to make a quick diversion and build a virtual version of the matrix in OpenSCAD:

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Using this model, I could walk through the output of the program and verify that the snake was truly moving correctly around the matrix. I rotated the model around, checking that the numbers were right and HOLY CRAP I MADE ANOTHER THING THAT WORKED!

 

The last thing to do was to actually get the program to work with the LEDs. This is where the spartan documentation of the original Radio Shack code became a problem; the sketch did a passable job of explaining how the lights were addressed, but the examples were all arrays of pre-baked values without having to do anything dynamic, and my program was all dynamic. I studied how the demo program worked, started fiddling with the values, and discovered how to set the bits in the right way to turn on individual lights, on specific levels. From there I modified my C program and added some code to translate my positioning, which turned out to be the mirror opposite of the way the lights are addressed; I solved the problem by physically turning the Arduino around so I was looking at the other side. Problem solved!)

I uploaded my sketch to the Arduino and it suddenly the lights were lighting up in what appeared to be a snake moving around the matrix. HOLY CRAP I GOT IT TO WORK!!!!!!11111

TL;DR:

This is a long post for what amounts to a small light toy, but whilst I was feeling rather verbose (a consequence of sitting and waiting for an unrelated program to finish), I can’t emphasize how foolish I feel for not starting all this earlier; fear of failure is a very, very powerful emotion and if there’s a TL;DR in here somewhere, it’s that it is always better to try and fail than to never try at all, which is something PS:1 has done a very good job of teaching me.

TL;DR(2):

The code is available at https://github.com/tachoknight/arduino-snakey.

10

08 2016