[Ryan] purchased a large fume extractor designed to sit on the floor below the work area and pull solder fumes down into its filtering elements. The only drawback to this new filter was that its controls were located near his feet. Rather than kicking at his new equipment, he devised a way to automate it.

By adding a Wemos D1 Mini microcontroller running ESPHome, a relay board, and a small AC-to-DC transformer, [Ryan] can now control the single push button used to cycle through speed settings wirelessly. Including the small transformer inside was a clever touch, as it allows the unit to require only a single power cable while keeping all the newfound smarts hidden inside.

The relay controls the button in parallel, so the physical button still works. Now that the extractor is integrated with Home Assistant, he can automate it. The fan can be controlled via his phone, but even better, he automated it to turn on by monitoring the power draw on the smart outlet his soldering iron is plugged into. When he turns on his iron, the fume extractor automatically kicks in.

Check out some other great automations we’ve featured that take over mundane tasks.

Cable harness design is a critical yet often overlooked aspect of electronics design, just as essential as PCB design. While numerous software options exist for PCB design, cable harness design tools are far less common, making innovative solutions like Splice CAD particularly exciting. We’re excited to share this new tool submitted by Splice CAD.

Splice CAD is a browser-based tool for designing cable assemblies. It allows users to create custom connectors and cables while providing access to a growing library of predefined components. The intuitive node editor enables users to drag and connect connector pins to cable wires and other pinned connectors. Those familiar with wire harnesses know the complexity of capturing all necessary details, so having a tool that consolidates these properties is incredibly powerful.

Among the wire harness tools we’ve featured, Splice CAD stands out as the most feature-rich to date. Users can define custom connectors with minimal details, such as the number of pins, or include comprehensive information like photos and datasheets. Additionally, by entering a manufacturer’s part number, the tool automatically retrieves relevant data from various distributor websites. The cable definition tool is equally robust, enabling users to specify even the most obscure cables.

Once connectors, cables, and connections are defined, users can export their designs in multiple formats, including SVG or PDF for layouts, and CSV for a detailed bill of materials. Designs can also be shared via a read-only link on the Splice CAD website, allowing others to view the harness and its associated details. For those unsure if the tool meets their needs, Splice CAD offers full functionality without requiring an account, though signing in (which is free) is necessary to save or export designs. The tool also includes a version control system, ideal for tracking design changes over time. Explore our other cable harness articles for more tips and tricks on building intricate wire assemblies.

Counting objects is an ideal task for automation, and when focusing on a single type of object, there are many effective solutions. But what if you need to count hundreds of different objects? That’s the challenge [Christopher] tackled with his latest addition to his impressive automation projects. (Video, embedded below.)

[Christopher] has released a series of videos showcasing a containerized counting system for various fasteners, available on his YouTube channel. Previously, he built remarkable devices to count and sort fastener hardware for automated packaging, but those systems were designed for a single fastener type. He effectively highlights the vast complexity of the fastener ecosystem, where each diameter has dozens of lengths, multiple finishes, various head shapes, and more.

To address this, he developed a machine that accepts standardized containers of fastener hardware. These uniform boxes can hold anything from a small M2 countersunk screw to a large M8 cap head bolt and everything in between. To identify the loaded box and determine the appropriate operations, the machine features an RFID reader that scans each box’s unique tag.

Once a box is loaded, the machine tilts it to begin counting fasteners using a clever combination of moving platforms, an optical sensor, and gravity. A shelf first pushes a random number of fasteners onto an adjustable ledge. A second moving platform then sweeps excess fasteners off, leaving only those properly aligned. It’s no surprise this system has nine degrees of freedom. The ledge then moves into view of a sensor from a flatbed scanner, which detects object locations with an impressive 0.04 mm resolution across its length—remarkable for such an affordable sensor. At this point, the system knows how many fasteners are on the ledge. If the count exceeds the desired number, a sloped opening allows the ledge to lift just high enough to release the correct amount, ensuring precision.

The ingenuity continues after the initial count. A secondary counting method uses weight, with a load cell connected to the bin where fasteners drop. A clever over-center mechanism decouples the tilting system from the load cell to ensure accurate readings. We love automation projects, and this one incorporates so many ingenious design elements that it’s sure to inspire others for their future endeavors.

The world of custom mechanical keyboards is vibrant, with new designs emerging weekly. However, keyboards are just one way we interact with computers. Ploopy, an open-source hardware company, focuses on innovative user interface devices. Recently, [Colin] from Ploopy introduced their latest creation: the Ploopy Knob, a compact and thoughtfully designed control device.

At first glance, the Ploopy Knob’s low-profile design may seem unassuming. Housed in a 3D-printed enclosure roughly the size of a large wristwatch, it contains a custom PCB powered by a USB-C connection. At its core, an RP2040 chip runs QMK firmware, enabling users to easily customize the knob’s functions.

The knob’s smooth rotation is achieved through a 6705ZZ bearing, which connects the top and bottom halves and spans nearly the device’s full width to eliminate wobble. Unlike traditional designs, the Ploopy Knob uses no mechanical encoder or potentiometer shaft. Instead, an AS5600 magnetic encoder detects movement with remarkable precision. This 12-bit rotary encoder can sense rotations as fine as 0.088 degrees, offering 4096 distinct positions for highly accurate control.

True to Ploopy’s philosophy, the Knob is fully open-source. On its GitHub Page, you’ll find everything from 3D-printed case files to RP2040 firmware, along with detailed guides for assembly and programming. This transparency empowers users to modify and build their own versions. Thanks to [Colin] for sharing this innovative device—we’re excited to see more open-source hardware from Ploopy. For those curious about other unique human-machine interfaces, check out our coverage of similar projects. Ploopy also has designs for trackballs (jump up a level on GitHub and you’ll see they have many interesting designs).

At one point in time mechanical seven segment displays were ubiquitous, over time many places have replaced them with other types of displays. [Sebastian] has a soft spot for these old mechanically actuated displays and has built an open-source 7-segment display with some very nice features.

We’ve seen a good number of DIY 7-segment displays on this site before, the way [Sebastian] went about it resulted in a beautiful well thought out result. The case is 3D printed, and although there are two colors used it doesn’t require a multicolor 3d printer to make your own. The real magic in this build revolves around the custom PCB he designed. Instead of using a separate electromagnets to move each flap, the PCB has coil traces used to toggle the flaps. The smart placement of a few small screws allows the small magnets in each flap to hold the flap in that position even when the coils are off, greatly cutting down the power needed for this display. He also used a modular design where one block has the ESP32 and RTC, but for the additional blocks those components can remain unpopulated.

The work he put into this project didn’t stop at the hardware, the software also has a great number of thoughtful features. The ESP32 running the display hosts a website which allows you to configure some of the many features: the real-time clock, MQTT support, timer, custom API functions, firmware updates. The end result is a highly customizable, display that sounds awesome every time it updates. Be sure to check out the video below as well as his site to see this awesome display in action. Also check out some of the other 7-segment displays we’ve featured before.

We’ve all seen the exploded view of complex things, which CAD makes possible, but it’s much harder to levitate parts in their relative positions in the real world. That, however, is exactly what [fellerts] has done with this wristwatch, frozen in time and place.

Inspired by another great project explaining the workings of a mechanical watch, [fellerts] set out to turn it into reality. First, he had to pick the right watch movement to suspend. He settled on a movement from the early 1900s—complex enough to impress but not too intricate to be impractical. The initial approach was to cast multiple layers that stacked up. However, after several failed attempts, this was ruled out. He found that fishing line was nearly invisible in the resin. With a bit of heat, he could turn it into the straight, transparent standoffs he needed.

Even after figuring out the approach of using fishing line to hold the pieces at the right distance and orientation, there were still four prototypes before mastering all the variables and creating the mesmerizing final product. Be sure to head over to his site and read about his process, discoveries, and techniques. Also, check out some of the other great things we’ve seen done with epoxy in the past.

If you’ve worked on a project with small LEDs, you know the frustration of determining their polarity. This ingenious LED Probe from [David] packs a lot of useful features into a simple, easy-to-implement circuit.

Most multimeters have a diode test function that can be used to check LEDs; however, this goes a step further. Not only will the probe light up an LED, it will light up no matter which side of the LED the leads are touching. A  Red/Green LED on the probe will indicate if the probe tip is on the anode or cathode.

The probe is powered by a single CR2032 battery, and you may notice there’s no on/off switch. That’s because the probe enters a very low-current sleep mode between uses. The testing intelligence is handled by either an ATtiny85 or, in the newest version, an ATtiny202, though the basic concept and design are compatible with several other chips. All the design files for the PCB, the ATtiny code, a parts list, and a detailed explanation of how it works are available on [David]’s site, so be sure to check them out. Once you build one of these probes, you’ll want something to test it on, so explore some of the LED projects we’ve featured in the past.