Peculiar Radial Mill from Car Parts

Whether 3D printer, lasercutter, or mill, most CNC machines use human-friendly, square-angle Cartesian geometry. This intriguing concept mill instead uses radial axes where motion is derived from scrap Chevy flywheels. It may look and feel weird at first, but it works – sort of.

Cartesian axes are intuitive. If you want to go to the right, increase X. If you want to go to away from you, increase Y. If you want to lift, increase Z. On a manual mill this is easy for making rectangles and blocks, or, with creative clamping, straight lines of any sort. But if you want to carve a circle? As we all learned on an Etch-A-Sketch, you increase your swearing and then throw it in the corner.

HAD - Radial Mill2[Jason] knew that with a CNC machine all geometry problems are reduced to math done by software. With two offset discs, any position is possible by rotating both the correct way. It may look odd that both plates drunkenly meander about just to draw a straight line but the computer is ambivalent. Software can be complicated without penalty and is free once written – more on that later. If a machine is physically simple then it can be built and repaired easily and cheaply. This design does away with almost all the familiar – and [Jason] argues complicated – components of normal hobby CNC machines. No slides, rails, carriages or belts here. His design uses only about a dozen parts.

Because automotive flywheels are made from cast iron the machine is rigid and naturally dampening. Sticking with the junkyard theme he pulled bearings from an F-450 truck, good for a few thousand pounds. Some steppers and a Raspberry Pi and he was done – well, sort of.

[Jason] let us know that his project has sat for long enough that he has become passionate about other things and decided to move on. He documented his progress and submitted the tip in hope to inspire someone else to continue the design further. Any type of CNC is possible, not just a mill. 3D printer perhaps?

Two big caveats: it needs a Z-axis (linear, probably standard) and there appears to be deeper-seated-than-expected G-code demands to chit-chat about rectangles and only rectangles. Nothing insurmountable, just nothing he has solved yet himself.

[Jason] said not to expect any further updates from him but he would love to see what the next person could do with it.

See the video after the break of the mill drawing our skull and wrenches logo, (soft of, without a Z-axis to lift).

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Adding a Steady Rest to a Lathe

A steady rest is a tool for a lathe, enabling a machinist to make deep cuts in long, slender stock, bore out thin pieces of metal, and generally keeps thin stuff straight. Unlike a tool that follows the cutter, a steady rest is firmly attached to the bed of a lathe. [Josh]’s lathe didn’t come with a steady rest, and he can’t just get parts for it. No problem, then: he already has a lathe, mill, and some metal, so why not make the base for one from scratch?

[Josh] was able to find the actual steady rest from an online dealer, but it wasn’t made for his lathe. This presented a problem when attaching it to his machine: because each steady rest must fit into the bed of the lathe, he would need a custom bracket. With the help of a rather large mill, [Josh] faced off all the sides of a piece of steel and cut a 45 degree groove. To make this base level, [Josh] put one side of the base on the lathe, put a dial micrometer on the tool post, and got an accurate reading of how much metal to take off the uncut side.

With the steady rest bolted onto the lathe, [Josh] turned a rod and found he was off by about 0.002″. To machinists, that’s not great, but for a quick project it’s fantastic. Either way, [Josh] really needed a steady rest, and if it works, you really can’t complain.

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Hand-Machined Companion Cube Can Be Destroyed and Rebuilt

[Michael Gainer] is a big fan of Portal, and it shows in the Weighted Companion Cube he made. [Michael] hand-machined the many pieces that comprise the Cube’s body and medallions out of 6061 aluminum. Dykem was used to transfer the marks for accurate machining, and the color is powder-coated to a heat tolerance of 400F. A CNC was used to make the distinctive hearts. [Michael] notes the irony was “very Portal” in having them cut by a heartless machine when everything else was done manually. The attention to detail is striking, the level of design more so when [Michael] proceeds to incinerate the poor Companion Cube with a brush burner. In the video shown at the link above, the Cube falls apart as the glue holding it together melts. When all is said and done, just grab more glue to bring that Cube back to its six-sided glory. Repeat to your heart’s content. Huge success! We have to be honest, after seeing all those pieces, we aren’t sure we’d want to do this very often. Companion Cubes have been featured in various iterations on Hackaday before, but they were never built with the idea of repeatedly destroying and rebuilding them. This novel take would make GlaDOS proud.

[Michael] has plans to put an Android device inside it with some light and temperature sensors. He wants to give it a voice resembling Portal’s turrets so it can whine when it needs to be charged or scream when it’s too hot or cold. He dubs this next project the “Overly Attached Weighted Companion Cube.” It wouldn’t be a good idea to incinerate this upcoming version, though we’d probably be inclined to if it demanded so much of our attention!


The Tumblemill: Homemade CNC Milling

[Jens] aka [Tumblebeer] has compiled an impressive overview of the Tumblemill, his homemade CNC mill. It warms our hearts to learn that [Tumblebeer] was inspired to pursue electronics by projects featured here on Hackaday, even if it means he dropped out of med school to pursue electrical engineering. We’re glad he’s following his passion, though, and reading through his blog reveals just how far he’s come: from fiery disaster in his first projects to a gradual obsession with making a CNC device, [Tumblebeer] has made plenty of mistakes along the way, but that’s how it should be.

His first iteration was a CNC router that used rubber wheels as linear bearings. It worked…barely. His latest build grew out of meticulous Solidworks modelling, with a moving gantry design constructed largely from aluminum, and upgraded linear motion: this time a bit overkill, using HIWIN HGH20CA blocks. Rather than sourcing a traditional spindle mount, [Tumblebeer] opted for the housing from a LM50UU bearing, which provided both the perfect fit and a sturdier housing for his 2.2kw spindle.

Visit his project blog for the details behind the mill’s construction, including a lengthy installment of upgrades, and hang around for a demo video below, along with the obligatory (and always appreciated) inclusion of the Jolly Wrencher via defacing an Arduino.

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Live Look at Taktia Augmented Power Tool and Carbide 3D Mill


There were so many things to see at Maker Faire that the booths spilled out of the buildings and into various tents on the grounds. One of the most interesting tents was packed with tables showing off CNC machines and that’s where we ran into two that are familiar, and still amazing.

First up is the handheld CNC router which we saw all the way back in 2012. It’s a spectacular piece of tech that adds a base to a handheld router. The base gives the tool a touchscreen system, the ability to precisely track it’s location, and adjustment motors to move the cutting bit in order to correct for imperfections in operator movements. It’s really amazing and we are happy to see they have formed a company called Taktia around the concept and are heading for crowd funding soon.

The second half of the video shows off the Nomad CNC mill which we covered at the end of April. Carbide 3D had a hugely successful (more than 10x the goal) Kickstarter that they tried to blame on the support of Hackaday readers. It’s a no-brainer that this machine is the one to watch, as even our hacked camera work doesn’t lose the fact that it can produce rock-solid results.

Hackaday Links: May 18, 2014


Think the original Pong is cool? How about point to point Pong? [v8ltd] did it in three months, soldering all the leads directly to the chip pins. No sockets required. It’s insane, awesome, a masterpiece of craftsmanship, and surprising it works.

[Jeremy Cook] is building a servo-powered light graffiti thing and needed a laser diode. How do you control a laser pointer with a microcontroller? Here’s how. They’re finicky little buggers, but if you get the three-pack from Amazon like [Jeremy] did, you get three chances to get it right.

NFC tags in everything! [Becky] at Adafruit is putting them in everything. Inside 3D printed rings, glued onto rings, and something really clever: glued to your thumbnail with nail polish. Now you can unlock your phone with your thumb instead of your index finger.

Photographs capture still frames, but wouldn’t it be great if a camera could capture moving images? No, we’re not talking about video because this is the Internet where every possible emotion, reaction, and situation can be expressed with an animated GIF. Meet OTTO, the camera that captures animated GIFs! It’s powered by the Raspberry Pi compute module, so that’s interesting.

[Nate] was getting tired of end mills rolling around his bench. That’s a bad thing. He came up with a solution, though: Mill a piece of plywood into a tray to hold end mills.

The Da Vinci printer, a printer that only costs $500 because they’re banking on the Gillette model, has been cracked wide open by resetting the DRM, getting rid of the proprietary host software, and unbricking the device. Now there’s a concerted effort to develop custom firmware for the Da Vinci printer. It’s extraordinarily bare bones right now, but the pins on the microcontroller are mapped, and RepRap firmwares are extremely modular.

Finally, A Desktop CNC Machine With A Real Spindle

While cheap hobby CNC mills and routers are great machines that allow you to build things a 3D printer just can’t handle, they do have their limitations. They’re usually powered by a Dremel or other rotary tool, so speed control of the spindle via Gcode is nigh impossible. They’re also usually built with a piece of plywood as the bed – cheap, but not high on repeatability. The Nomad CNC mill fixes these problems, and manages to look good and be pretty cheap, to boot.

Instead of using a Dremel or other rotary tool to cut materials, the Nomad team is using a brushless DC motor connected to a real spindle. With a few certain motors, this allows for closed loop control of the spindle;  Sending S4000 Gcode to the mill will spin the spindle at 4000 RPM, and S6000 runs the spindle at 6000 RPM, whether it’s going through foam or aluminum. This is something you just can’t do with the Dremel or DeWalt rotary tools found in most desktop mills and routers.

Along with a proper spindle, the Nomad also features homing switches, a tool length probe, and a few included fixtures that make two-sided machining – the kind you need it you’re going to machine a two-layer PCB – possible, and pretty simple, too. The softwares controlling the mill are Carbide Motion and MeshCAM, a pretty popular and well put together CNC controller. Of course the mill itself speaks Gcode, so it will work with open source CNC software.

It’s all a very slick and well put together package. Below you can find a video of the Nomad milling out a Hackaday logo.

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