A Brilliant and Elegant CNC Pendant

pendant

[Mike Douglas] has a small hobby CNC router, which works great — but you’re limited to controlling it from your PC. And unfortunately, there just aren’t pendants made for this consumer level stuff. Annoyed at having to reach over to use his keyboard all the time, he stumbled upon a simple, but brilliant solution: A dedicated USB 10-key pendant keypad.

These USB keypads are designed for laptops that don’t have full size keyboards. They can be had for a few dollars from China, and let you expand your keyboard possibilities… All [Mike] had to do was print off some stickers to put on the keys!

It’s easy to program new hot keys in Mach3  – and there you go! Why haven’t we thought of this before? While you’re at it, why not build a cyclonic dust separator for your CNC too — and if you’re having trouble clamping down work pieces, [Mike] has a pretty cool solution for that as well.

 

 

Building a Quadcopter with a CNC Mill and a 3D Printer

Quadcopter

Quadcopters are a ton of fun to play with, and even more fun to build. [Vegard] wrote in to tell us about his amazing custom DIY quadcopter frame that uses a commercial flight control system.

Building a quadcopter is the perfect project to embark upon if you want to test out your new CNC mill and 3D printer. The mechanical systems are fairly simple, yet result in something unbelievably rewarding. With a total build time of 30 hours (including Sketchup modeling), the project is very manageable for weekend hackers. [Vegard's] post includes his build log as well as some hard learned lessons. There are also tons of pictures of the build. Be sure to read to read the end of the post, [Vegard] discusses why to “never trust a quadcopter” and other very useful information. See it in action after the break.

While the project was a great success, it sadly only had about 25 hours of flight-time before a fatal bird-strike resulted in quite a bit of damage. Have any of your quadcopters had a tragic run-in with another flying object? Let us know in the comments.

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The Auto Parking Mecanum Robot

mecanum

A while back, Hackaday visited the Clark Magnet School in Glendale, California to sneak a peek on their STEM-focused curriculum, FIRST robotics club, awesome A/V classroom, and a shop that puts most hackerspaces to shame. We saw a few builds while we were there, but [Jack]‘s auto parking mecanum robot was in a class by itself. It deserves its own Hackaday post, and now that [Jack] is on Hackaday Projects, he’s sharing all the details.

The most impressive aspect of [Jack]‘s build is the mecanum wheels; the side plates for the wheels were designed by [Jack] himself and machined on his school’s Haas mill. When the plates came out of the mill they were flat, and each of the fifteen little tabs on the plates needed to be bent at a 45 degree angle. With a CNC jig and a lot of time on his hands, [Jack] bent the tabs for all eight plates.

In addition to the plates, the rollers were custom made from non-expandable polyurethane poured into a CNC milled mold. That’s a one-part mold; [Jack] needed to make sixty of these little parts, one at a time.

The electronics are built around an Arduino Mega communicating with a joystick via an XBee. [Jack] found the relays in the off-the-shelf motor board couldn’t handle the current, so he replaced them with much, much larger ones in a hack job we’d be proud to call our own handiwork. There’s also a little bit of code that allows this motorized cart to pull off the best parallel parking job anyone could ever wish for. You can see that and a few videos of the construction below.

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DIY CNC Dust Collection Really Sucks!

CNCdust-main2

CNC Routers are great. If you’ve ever used one you know this but you also know that they will cover the machine and everything around it with a layer of dust. It is certainly possible to use a shop vac to suck up the dust coming from the router, however, the only problem with that is the shop vac’s filter will clog with dust and lose suction, defeating the intent of your vac system.

CNCdust-assembled2[Mike Douglas] was ready to step up his CNC game and decided to make his own dust separator. This design is extremely simple and only uses a couple 5 gallon buckets, a few PVC fittings and pieces of wood. To keep the cost down and the style up, the accompanying ‘shop-vac’ is also made from 5 gallon bucket with a vacuum lid. The project is well documented so head over to his site and check out the build process.

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A 3-Axis Paper Cutting Mini Laser

LaserCutter

Laser are awesome, and so are projects that use lasers. A recent Instructable by [kokpat] gives an overview of how to create a fully functional laser paper cutter using CDROM stepper motors and an Arduino.

What is special about this build, is that it showcases how easy it can be to build a 3-axis mechanical system used for laser cutters, CNC machines, and 3D printers. Using a stepper stage that consist of a motor screw with a nut slider based carriage, the mechanical system can be put together quite easily and cost effectively. Luckily, from an electronics and software perspective, everything is quite standardized with the proliferation of the RepRap and similar machines. Simply pick any three stepper drivers, find the most pertinent firmware, and voilà! You’re done! Well, almost. Don’t forget a 100mW violet laser!

We have seen a ton of really cool laser cutters before, but this has to be one of the cheapest. See the laser cutter in action after the break.

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DAGU: The Standalone CNC Controller

CNC

In terms of user interfaces, 3D printers are far, far beyond the usual CNC machine. It’s difficult to find a new, commercial 3D printer without some sort of display, set of buttons, and an SD card slot for loading G Code and running a printer. For CNC routers, though, you’re usually dealing with a parallel port interface connected to an old computer.

DAGU hopes to change that by providing a huge 240×128 LCD display, a bunch of buttons, and an SD card slot for loading G Code directly from an SD card. This is a fully functional controller, able to deliver 3.5 A to each stepper motor winding.

Right now DAGU is in the prototype stage, but already there are some really interesting features: the interface allows for a basic preview of the job before it begins, and should be somewhat affordable. At least as cheap as using an old computer for CNC control, anyway.

Video demo of the use and operation of DAGU below.

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Chinese 3020 CNC Machine Gets Some Upgrades

3020small

If you frequent any CNC Forums out on the ‘web you’ll find that these Chinese 3020 CNC routers are generally well received. It is also common opinion that the control electronics leave something to be desired. [Peter]‘s feelings were no different. He set out to make some improvements to his machine’s electronics such as fixing a failed power supply and adding PWM spindle control and limit switches.

[Peter] determined that the transformer used in the power supply was putting out more voltage from the secondary coil than the rest of the components could handle. Instead of replacing the transformer with another transformer, two switch mode power supplies were purchased. One powers the spindle and the other is for the stepper motors. So he wasn’t guessing at the required amperage output of the power supplies, [Peter] measured the in-operation current draw for both the steppers and spindle motor.

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