Delta-type 3D printer built using extruded rails

delta-3d-printer-extruded-rail

From concept to completion this delta-style 3D printer (translated) is a sweet build. The quality of the work comes as no surprise. We’re familiar with [Arkadiusz Spiewak’s] craftsmanship from that H-bot type 3D printer we saw from him back in April.

Planning started off with a render of the design using Blender 3D. Not only did this give him a 3D model to use as his building reference, but the animation framework allowed him to test the kinematics of the design. After ordering an extruded rail system and assembling the frame he found the pillars had too much flex to them due to the rails used on the top and bottom. The fix was to mill a top and bottom plate to stiffen things up. After testing out the motors and the extruder head mount he made one final design change. He exported his Blender design as dxf files to cut and weld an aluminum replacement for the extruder mounting platform. As you can see in this video, the preliminary results are looking good!

Continue reading “Delta-type 3D printer built using extruded rails”

A respectable electronics bench that’s not a pain to move

electronics-workstation-that-moves

Apartment dwellers who are living the nomadic lifestyle take note. You don’t need to live your tinkering lifestyle out of a toolbox. Here is a great example of a respectable electronics bench which breaks down when it’s time to move (translated). We’re sure you already belong to your local hackerspace for the big projects, but this corner office will let you take some of your creations home for continued tweaking.

The bench uses slotted aluminum rails as the support structure. The slots accept small nuts, which have a spring-loaded ball bearing to keep them from sliding freely ([Nerick] mentions this is especially nice for working with the vertical runs). These fasteners ended up being the most costly component.  The desktop itself is the largest solid piece. It was machined using a CNC mill (we already mentioned having a hackerspace membership) so that the mounting screws are countersunk to leave a perfectly flat surface. It’s clean, has a small footprint, and gives you a place to dump all of your gear. What else could you ask for?

Cutting styrofoam with a CNC machine and turning it into aluminum

One of the most popular ways of turning an object trapped inside the world of a computer into a real, metal object is the art of lost wax, or lost foam casting. In this process, a full-scale model of the object to be made in metal is crafted in either foam or wax, placed in a pile of sand, and burned away by molten metal.

[ptflea] over at the Bamberg, Germany hackerspace Backspace came up with a very clever build that automatically cuts foam into the desired shape, ready to be taken out to the backyard foundry. The build is based around an old flatbed scanner and a hot wire cutter. The old scanner conveniently had  an equal number of steps per axis, so attaching an Adafruit motor shield and replacing the old control electronics was just an issue of finding the correct resistors.

Software control is provided by a Processing app [ptflea] whipped up and is able to carefully cut very delicate shapes that even the steadiest hand would have trouble with.

Making stuff out of styrofoam is cool and all, but the real goal for this project was setting things on fire and melting old heatsinks. The styrofoam molds were placed in a bucket full of sand, and the furnace – a few ytong bricks, a crucible, and a propane burner – started to melt some aluminum. The molten aluminum was poured onto the mold and after cooling, the makers of Backspace had a few very cool aluminum trinkets.

A nice build that is able to produce some very nice metal objects. We suspect, though, that a higher-density foam (something along the lines of blue or green insulation sheets, if they have those in Germany) could produce an even higher level of detail if you’d like to build your own.

Videos after the break.

Continue reading “Cutting styrofoam with a CNC machine and turning it into aluminum”

Professional looking dog robot was actually [Martin’s] Master’s Thesis

If you think this thing looks good you should see it move. [Martin Smith] hit a home run on the project, which was his Master’s Thesis. Fifteen servo motors provide a way for the bot to move around. Having been modeled after a small canine the gait is very realistic. The tail is even functional, acting as a counterweight when moving the legs.

The project was meticulously built in a 3D environment before undertaking any physical assembly. The mechanical parts are all either milled from aluminum or 3D printed. Two mBed boards mounted on its back allow it to interact with its environment. One of them handles image processing, the other drives the array of motors. And of course it doesn’t hurt that he built some Larson Scanners in as eyes.

Don’t miss the video after the break which shows off the entire project from planning to demonstration. We can’t help but be reminded of the rat-thing from Snow Crash.

Continue reading “Professional looking dog robot was actually [Martin’s] Master’s Thesis”

How anodization is used to make pretty iPod colors

What do those colorful iPod Nano cases have in common with sapphires? In both substances the color is not on the surface, but integrated in the structure of the material. As usually, [Bill Hammack] unveils the interesting concepts behind coloring metal through anodization in his latest Engineer Guy episode.

We’re not strangers to the anodization process. In fact we’ve seen it used at home to change the color of titanium camping utensils. [Bill] explains what is actually going on with the electrochemical process; touching on facts we already knew; like that the voltage range will affect the color of the annodized surface. But he goes on to explain why these surfaces are different colors and then outlines how anodized metals can be dyed. That’s right, those iPod cases are colored with dye that will not wash or scratch off.

Pores are opened when the aluminum goes through anodization. Those pores are filled with dye, then the metal is boiled in water which closes them, sealing in the color. Pretty neat!

Continue reading “How anodization is used to make pretty iPod colors”

All Aluminum Longboard Shows Its Mettle

Reddit user [davvik] made an album to show off his custom all aluminum longboard.  The whole setup weighs about 12lbs, which is not exactly light for a board.  In spite of the added weight [davvik] comments that it is actually pretty responsive. The design is not uncommon but seems to have opted out of the speed holes in favor of structural rigidity, and frankly we love it.

We might not risk wearing sandals on the thing, but [davvik] says for the most part the whole setup has the feel of a wooden longboard, and the added weight makes it fun downhill.  Future plans for the board include machining out the ends, we think this would be a great opportunity for some DIY anodizing!

[via Reddit]

Carabiner helps you hone your milling skills

[Christian] is learning to use the metal milling tools at what we assume is his local Hackerspace. We love this about the communal spaces, they provide so many opportunities to delve into new fields. He embarked on a voyage that included visits to most of the machinery in the shop as he build his own carabiner with a magnetic gate. He’s not going to be hanging off the side of a mountain from it. But his keys or a water bottle will find a happy home thanks to the device.

It all started with some sketches to establish the shape of the overall design. From there he spent some time modelling the frame of the carabiner in CAD. He’s lucky enough to have access to a water jet which took the SolidWorks files and cut out the aluminum frame for him. That left a part with very sharp edges, so he used a wood router with a carbide bit to round them over.

The next part is adding the gate. He used an end-mill to add a mounting area on the frame. The locking ring for the gate was textured using a knurling tool, and the rest is milled with a simple cutting tool. This gate uses a magnet to center itself, with the knurled ring as the only mechanical latching mechanism. [Christian] does a good job of demonstrating the completed carabiner in the clip after the break.

Continue reading “Carabiner helps you hone your milling skills”