Turning 3D prints into aluminum castings

[Jeshua] needed a laser head attachment for a 5×10 foot CNC machine he’s working on. Because he has a 3D printer, [Jeshua] could easily print a laser mount and attach it to his CNC gantry, but that wouldn’t look very professional. Instead of decorating his gigantic machine with brightly colored plastic, he decided for a more industrial look by casting a laser head in aluminum using a 3D printed master.

[Jeshua] designed two parts for his laser cutter in OpenSCAD and printed them out on his 3D printer. A few bits of foam insulation were glued on to act as sprues, and an investment mold was made out of 1 part Plaster of Paris and 1 part playground sand.

After the mold had cured, [Jeshua] put is mold in a coffee can furnace to burn out the wax and foam. These hollow molds were placed in sand and the crucible loaded up with aluminum scrap.

The finished laser head fit his CNC machine perfectly – no small feat, considering [Jeshua] needed to take in to account how much the aluminum would contract after cooling. Not bad for one day’s work.

Building a casting furnace with heat exchanger

This completely DIY casting furnace turned out just great thanks to all the work [Biolit11] put into it along the way. He wanted to replace his older furnace with one that was more efficient, and to that end he built a heat exchanger into the design. This way the exhaust will preheat the intake air.

The furnace itself started with the shell of an old electric water heater. Excluding the design process, the majority of the build involved mold making. For circular parts he’s using quick tube, the paperboard forms used for pouring concrete footings. For more intricate parts he shaped polystyrene. They are layered in place and high-temperature cement is poured to form the permanent parts. After it hardens the polystyrene can be removed in chunks.

The heat exchanger is the part to the left. It includes several wide, flat pipes made of cement for removing the exhaust. Around those pipes a snaking metal chase carries the intake air which picks up the heat as it passes over the exhaust pipes.

For his first run with the new furnace he melted down a bunch of scrap aluminum and poured ingots.

[Thanks DC3]

Writing Javascript without using any letters or numbers

Did you know it’s possible to write Javascript code without using any letters or numbers at all? Well, it’s not just Javascript, but that’s the language used in this demonstration. [Patricio Palladino] shows how code can be written using just eight characters, and all of them are punctuation marks.

Typecasting is the name of the game here. By starting out with an empty array formed by a pair of square brackets, [Patricio] can generate the number zero by casting the array with the plus sign. From there he can use an exclamation point (a boolean cast) and addition to generate any number. The image above is an example of the digits 0-9. This would get very tedious for larger numbers but there’s another shortcut. Cast the digits to strings, concatenate them, then cast back to a number and you’re in business.

The technique is fascinating, and basically unreadable. As a proof of concept he wrote a parser that will convert any Javascript into this hieroglyphy. Check out his Github repository to give it a try.

[via Reddit]

Iron casting in the parking lot

Here’s one good thing about the bitter cold Midwestern winter, it helps keep you from overheating when working around a hot furnace. Back in February this iron pour happened in the parking lot of the Madison, Wisconsin based Sector67 Hackerspace. Look, they’re making iron hearts!

Now this isn’t just a bunch of members who got together and decided to do some casting. As you can tell in the video after the break the team knows what they’re doing. The event was a collaboration with FeLion Studios, a custom cast-iron art boutique. But the Hackerspace participants did get to take part in the process of building the cast, watching the pour, and cleaning up the rough results.

One of the people from FeLion Studios just appeared on the Martha Stuart Show, along with a 550 pound cast-iron frying pan United States map.  [Chris] from Sector67 tells us the New York frying pan that [Martha] is hold was a product of the parking lot pour.

Continue reading “Iron casting in the parking lot”

Sand casting motorcycle cases

Sand casting has been around since, well, since a really really long time ago. For thousands of years, people have been pouring molten metal into finely crafted sand casts, and there’s really no reason that someone can’t do the same thing in their garage or workshop today. This article covers the process of sand casting new case parts for antique Indian motorcycles.  In this instance, the parts were not only very difficult to find, the author also wanted to modify the design completely.

Though there are a few terms that pop up with which we’re unfamiliar, the process seems pretty straightforward. You build a model of what you want, you create the sand cast from the model, you fill the cast with molten metal. Done. In some cases, depending on the level of precision needed, you may need some machining done afterward. However, in many cases things don’t have to be quite so exact.

[via Matthew Van Arsdale]

Hackaday Links: April 20, 2012

Introducing Hackaday: how it’s made edition

Ever wonder how the make the forms for marine propellers? Now you have. It turns out they use a bunch of plywood, Bondo, and sandpaper. Awesome viewing for a coffee break.

Finally a new way to hurt yourself!

[Darrell]’s solder flux pen was filled and capped at sea level. When this pen made it to his work bench high in the mountains of Colorado there was a significant amount of pressure in that pen. The flux squirted out right into [Darrell]’s eye. Better get some Visine on that, man.

The most accurate television portrayal of hacking ever

[Russell] was watching TV last night and saw an interesting commercial. It’s a bunch of electronic components, then a nook color showing the front page of Make: Projects, an Arduino schematic, and finally a happy robot. Two observations: firstly, someone in media and advertising doesn’t think ‘hacking’ is WarGames stealing bank accounts. Secondly, an ad exec looked into current users.

Here’s the official YouTube video of the commercial.

In a world… where components aren’t soldered… one man… uses a soldering station.

Adafruit linked to the most outrageous promo video ever. This Weller soldering station provides 240 watts, battles alongside Agamemnon at Troy,  has rework tweezers, and travels to Italy to wage war against the Latins.

An IDE for the 21st century

[Chris] is currently developing a new paradigm for programming. He calls it Light Table, and it’s designed to be an improvement over a simple text editor and project manager. All the documentation is at your fingertips, you can make changes on the fly. It reminds us of the zzstructure emulator we saw last year. It’s something to keep an eye on at least.

Free formed circuit protected by a brick of crystal clear resin

The look of this crystal clear resin brick is pretty amazing. [Rupert Hirst] decided to encase his amplifier circuit in a block of polyester resin. We just hope he got everything in his circuit right because there’s no way to replace any of those parts now!

He deserves a lot of credit for working out a visually pleasing way to mount each component. There wasn’t any type of substrate used, but a few lower gauge wires were picked as the rails and they add some mounting stability. Before casting, he took the case of each of the three jacks apart and sealed the seams with some of the casting resin to prevent the final pour from filling them up.

Eagle CAD was used to design the mold. He printed it out on some card stock, then used a hobby knife to cut the pieces out and super glue to assemble them. A second layer of super glue was run on each seam to ensure they’re water tight. After the casting was made [Rupert] spent plenty of time sanding, routing, and polishing the brick to achieve this look.

This makes us wonder about heat dissipation. Do you think it will be a problem? Tells us what your opinion by leaving a comment.