“You can’t control what you can’t measure” goes the old chestnut. But that’s a little bit negative, in my opinion. Instead, think of the benefits of sprinkling sensors around everywhere: you gain insight where you simply didn’t have it beforehand.

We were thinking about this in the context of the recent video on pressure advance in 3D printers. Essentially, the unmelted filament acts as a springy piston, and that springiness means that the pressure built up in the melted plastic lags the feedrate of new filament. We usually calibrate this out with a guesstimate constant, but it can be different for every different filament. Measuring that pressure directly with a strain gauge in the hot end makes more sense.

But then there are knock-on benefits of having a sensor in the hot end. You can use the strain gauge as Prusa does to run the nozzle gently into the bed and set the z-axis height. Or you can use over-pressure as a sign that the nozzle is clogged. It’s quite possible that you can use it to signal other things that can go wrong as well, but you can’t tell until you put the sensor on in the first place.

Of course, you don’t want to put a pressure sensor where you want to know the temperature, or vice-versa. But as a general rule, the more you can measure, the more you can discover about the way your system is running. How many strain gauges are too many?

[Jenny] and I were talking about [Bitluni]’s experiment in scale, where he will take 65,536 cheap microcontrollers, network them all together, and give each one an RGB pixel. From there, antics will surely ensue. Right now, he’s only got 8,192 of them up and running, and already the novel problems and opportunities are rearing their heads.

We all know it from our own hacking. In theory, doing something ten times is ten times doing it once. But then in practice, entirely new phenomena appear as you scale up that were simply not there in the small. Maybe it happens when you repeat it one hundred times, or a thousand.

Viewed positively, this is the property of emergence: how the whole can be more than the sum of its parts, and how biology isn’t just chemistry multiplied by a few million interactions. In our blinky world, a massive wall of LEDs is a display, not just a bunch of pixels.

On the flip side, going from one microcontroller with a 10 mA current draw to 64 Ki controllers, with 655 A, is more than just a difference in scale. You need to learn a new skill set to handle the problem. Making a single prototype is a different problem from making a run of badges for a conference of 5,000 – you’ll need a team, and won’t be able to just hack it alone – not to even mention the parts sourcing woes.

So I loved watching [Bitluni] going through the upscaling. He certainly had an idea of what he was getting himself into, but as with the emerging properties of a big system, there are often emerging problems, and those you can’t always see ahead of time. Have you gotten into a project that scaled itself into something qualitatively different? Tell us about it.