Building a robot without using a machine shop
posted Jun 24th 2011 4:01pm by Mike Szczysfiled under: robots hacks, tool hacks

We usually avoid the prospect of buying new tools just for one project. In the long run we’re sure we’d use them again, but sometimes even with that outlook you can’t afford it. Case in point is our life-long-lust for a laser cutter; we just can’t justify the upfront cost but we sure would use it constantly if we had one.
If you do find that you’re interested in taking on a project that calls for laser cut parts, [I Heart Robotics] shows you how to do it with a few simple hand tools. The bot seen above is their TurtleBot. You can cut your own parts using a laser cutter, you can buy a kit from them, or you can bust out a ruler, compass, drill, coping saw, printer, and tape to make the pieces by hand.
It’s a simple enough concept. Print out the templates, tape them to your hard board, then start drilling and sawing. You won’t get the precision a machine tool can, but in some cases you don’t need to be all that perfect.
[via Adafruit]






Don’t fret over not having a laser cutter. They are not that impressive. The burns, the rough edges; what they do well is straight lines. Google up some woodworking techniques to calibrate whatever you have be it a tablesaw, bandsaw etc.. and you can get results that only very expensive laser cutters can produce. The parts will even have a better surface finish should you use quality blades and jigs.
The first ‘fine woodworking’ project I took on was making a sharpening jig that required three points of precision to get the perfect mirror edge on plane irons and chisels. With just a digital caliper and some crappy off the shelf stuff (since I needed to make a sharpening jig to make them not crappy) it was totally possible to turn a chunk of hickory into the perfect 1.187 inch tall block.
If you are curious that specific number was needed to have the extension setup to a nice round number on my favorite plane iron, saving quite some effort later.