Thermoforming: Shaping Curvy Grilles With No Supports

Making sure the heatgun is on ‘low’ and gloves are on while pushing on the mold. (Credit: Zion Brock)
Although hobbyists these days most often seem to use thermoplastics as a print-and-done material in FDM printers, there’s absolutely nothing stopping you from taking things further with thermoforming. Much like forming acrylic using a hot wire or hot air, thermoplastics like PLA can be further tweaked with a similar method. This can be much less complex than 3D printing the design with supports, as demonstrated by [Zion Brock].

For this classically styled radio project the front grille was previously 3D printed with the curved shape, but to avoid an ugly edge it had to be printed with most of the grille off the print bed, requiring countless supports and hours of printing time. To get around this, [Zion] opted to print the grille flat and then thermoform its curved shape. Of course, due to the unusual shape of the grille, this required a bit more effort than e.g. a spherical form.

This is similar to what is used with sheet metal to get detailed shaped, also requiring a mold and a way to stretch the flat shape over the mold. With the flat form designed to have all the material in the right places, it was able to be printed in less than an hour in PLA and then formed with a heatgun aimed at the part while the two-section mold is slid together to create the final form.

You can find the design files and full instructions on the website for the radio project.

youtube.com/embed/z20IXm1w-Fo?…

hackaday.com/2026/02/11/thermo…

FLOSS Weekly Episode 864: Work Hard, Save Money, Retire Early

This week Jonathan chats with Bill Shotts about The Linux Command Line! That’s Bill’s book published by No Starch Press, all about how to make your way around the Linux command line! Bill has had quite a career doing Unix administration, and has thoughts on the current state of technology. Watch to find out more!

• linuxcommand.org/
• nostarch.com/linux-command-lin…

youtube.com/embed/9zpSG6sAJiY?…

Did you know you can watch the live recording of the show right on our YouTube Channel? Have someone you’d like us to interview? Let us know, or have the guest contact us! Take a look at the schedule here.

play.libsyn.com/embed/episode/…

Direct Download in DRM-free MP3.

If you’d rather read along, here’s the transcript for this week’s episode.

Places to follow the FLOSS Weekly Podcast:

• Spotify
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Theme music: “Newer Wave” Kevin MacLeod (incompetech.com)

Licensed under Creative Commons: By Attribution 4.0 License

hackaday.com/2026/02/11/floss-…

Motorola’s Password Pill Was Just One Idea

Let’s face it; remembering a bunch of passwords is the pits, and it’s just getting worse as time goes on. These days, you really ought to have a securely-generated key-smash password for everything. And at that point you need a password manager, but you still have to remember the password for that.

Well, Motorola is sympathetic to this problem, or at least they were in 2013 when they came up with the password pill. Motorola Mobility, who were owned by Google at the time, debuted it at the All Things Digital D11 tech conference in California. This was a future that hasn’t come to pass, for better or worse, but it was a fun thought experiment in near-futurism.

Dancing with DARPA

Back then, such bleeding-edge research was headed by former DARPA chief Regina Dugan. At the conference, Dugan stated that she was “working to fix the mechanical mismatch between humans and electronics” by doing things such as partnering with companies that “make authentication more human”.
Image by HeungSoon from Pixabay
Along with Proteus Digital Health, Dugan et. al created a pill with a small chip inside of it and a switch. Once swallowed, your various stomach acids serve as the electrolyte. The acids power the chip, and the switch goes on and off, creating an 18-bit ECG-like signal.

Basically, your entire body becomes an authentication token. Unlock your phone, your car door handle, and turn on your computer, just by existing near them.

It should be noted that Proteus already had FDA clearance for a medical device consisting of an ingestible sensor. The idea behind those is that medical staff can track when a patient has taken a pill based on the radio signal. Dugan said at the conference that it would be medically safe to ingest up to thirty of these pills per day for the rest of your life. Oh yeah, and she says the only thing that the pill exposes about the taker is whether they took it or not.

Motorola head Dennis Woodside stated that they had demonstrated this authentication technology working and authenticating a phone. While Motorola never intended to ship this pill, it was based on the Proteus device with FDA clearance, presumably so they could test it safely.

The story of Proteus Digital Health is beyond us here, but for whatever reason, their smart pills never took off. So we’re left to speculate about the impact on society that this past future of popping password pills would have had.

About That Government Influence

Redford and Poitier in Sneakers (1992). Image via IMDb
While it sounds sorta cool at first, it also seems like something a government might choose to force on a person sooner or later. Someone they wanted to insert behind enemy lines, perhaps, or just create an inside job that otherwise wouldn’t have happened.

Taking off my tin foil hat for a moment, I’ll compare this pill with existing modern biometrics. A face scan, a fingerprint, or even my voice is my passport, verify me are all momentary actions.

With these, you’re more or less in control of when authentication happens. A pill, on the other hand, must run its course. You can’t change the signal mid-digestive cycle. Plus, you’d have to guard your pills with your life, and if a couple pills pass through you every day, you’d better have a big pillbox.

Authentication Can Be Skin Deep

Image by MC10 via Slashgear
So the password pill never came to pass, but it’s worth mentioning that at the same conference, Dugan debuted another method of physical authentication — a temporary password tattoo they developed along with MC10, a company that makes stretchable circuits and has since been acquired by a company called Medidata.

More typically, their circuits are used to do things like concussion detection for sports, or baby thermometers that continuously track temperature.

Dugan said that the key MC10 technology is in the accordion-like structures connecting the islands of inflexible silicon. These structures can stretch up to 200% and still work just fine. The tattoos are waterproof, so go ahead and swim or shower. Of course, the password tattoo never came to be, either. And that’s just fine with me.

hackaday.com/2026/02/11/motoro…

Vintage Film Editor Becomes HDMI Monitor

With the convenience of digital cameras and editing software, shooting video today is so easy. But fifty years ago it wasn’t electronics that stored the picture but film, and for many that meant Super 8. Editing Super 8 involved a razor blade and glue, and an editing station, like a small projector and screen, was an essential accessory. Today these are a relatively useless curio, so [Endpoint101] picked one up for not a lot and converted it into an HDMI monitor.

Inside these devices there’s a film transport mechanism and a projection path usually folded with a couple of mirrors. In this case the glass screen and much of the internals have been removed, and an appropriate LCD screen fitted. It’s USB powered, and incorporates a plug-in USB power supply mounted in a UK trailing socket for which there’s plenty of space.

There’s always some discussion whenever a vintage device like this is torn apart as to whether that’s appropriate. These film editors really are ten a penny though, so even those of us who are 8 mm enthusiasts can see beyond this one. The result is a pleasingly retro monitor, which if we’re honest we could find space for ourselves. The full video is below the break. Meanwhile it’s not the first conversion we’ve seen, here’s another Hanimex packing a Raspberry Pi.

youtube.com/embed/YTQoNQL0R9E?…

hackaday.com/2026/02/11/vintag…