CNC router built with 80/20 rail

There’s still quite a bit of machining that goes into a CNC mill build of this size. But using 80/20 brand extruded rail optimizes most of the build process into tasks manageable by the average basement hacker. That’s not to say that we think [Jim] is average. He took this mill from start to finish in just two weeks.

He picked up the set of three ball screws on eBay for $180. Two of them drive the X axis with the third moving the cutter assembly along the Y axis. The X axis travels along a set of precision rails instead of precision rods. He machined his own mounting plates to which those are attached. For now he’s not running the motors at full speed because the vibration starts to make the table shake. He may end up bolting the base to the floor once all is said and done.

We see this extruded rail used all over the place. We could highlight some other mill builds or 3d printers, but instead we think you’ll enjoy an extruded rail robotic bass guitar.

Oh, one last thing. We’re not against a bit of pandering. Below you can see the mill cutting out the Hackaday logo:

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Cyclone PCB Factory: 3d printable circuit board mill

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If you can 3D print most of the parts for another 3D printer, why not also for a PCB mill? That’s the question answered by the Cyclone PCB Factory. It will help you kiss those toner transfer or photo resist days goodbye.

Homemade circuit boards tend to be rather small, which really helps keep the cost and scope of this project down. Most of the mounting parts, as well as the gears, are 3D printed. Of course there’s the usual machine tool items which you pretty much have to purchase: the ball screws, precision rod, stepper motors, and a motor to spin the routing tool.

Check out the video below to see where the project is right now. One of the crucial aspects of PCB milling is to have a level build table. The cutter head tends to be ‘V’ shaped so cutting just a bit too deep can blow out the traces you’re trying to isolate. The demo shows that this can automatically calibrate the software to account for any variances in the height of the copper clad.

We remember seeing a snap-together PCB mill. But we’re pretty sure that that one used parts milled from HDPE rather than 3D printed components.

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DIY Pick and Place just getting under way

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It’s not totally fair to say that this project is just getting under way. But the truth is it neither picks nor places so there’s a long road still to travel. But we’re impressed with the demonstrations of what [Daniel Amesberger] has achieved thus far. Using the simplest of CNC mills he’s finished the frame and gantry for the device. You can see some of the parts on the left after going though an anodizing process that leaves them with that slick black finish.

The demo video shows off the device by driving it with a joystick. It’s fast, which gives us hope that this will rival some of the low-end commercial pick and place machines. He’s already been working on the software, which runs on a mini ITX form factor computer. This includes a gerber file interpreter and some computer vision for a visual check on part placement. He hasn’t gotten around to building the parts feeders but we’ll keep you updated as we hear back from him.

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Briefcase mill

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Take the machine shop with you; that’s the mantra which drove [Ryan] to build this CNC mill in a briefcase. That album will give you a taste of the final product. But you’ll want to dig through two pages of his forum thread starting with this post in order to behold the build process.

The image above is only part way through the fabrication, but we thought it gave the best overall view of his work. It’s missing the cables which connect to the control circuitry in the lid. The bed has also not been installed and this was before he fabricated the protective case for the PCBs.

Getting everything to fit inside of a folding case was quite a trick. Of course he used CAD to make sure it was possible. There are several places where the clearance when closed is about 2mm. We’re shocked by the build quality of the mill itself. It’s a novel idea to make it portable, but the accuracy and reliability of the machine didn’t suffer for the concept.

If you need a desktop mill that’s not quite as portable here’s a project which will dish out some inspiration.

ShapeOko build log — it’s a CNC mill in a box

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We’re not blatantly trying to promo this product. It’s just that the build log covering a ShapeOko assembly process taken on by [Anool] is like crack for those of us who have yet to acquire our own desktop CNC mills.

Like the title says, this thing is basically a mill in a box. But [Anool] decided to order the version of the kit that doesn’t come with any motors or control electronics. He also planned for future upgrades by ordering additional extruded rail to increase the size of the ShapeOko. After assembling the frame his decision to source stepper motors locally bit him as they were out of stock. But there was still plenty to do preparing control electronics during the wait. He based his system on a Raspberry Pi which talks to an Arduino to address the motors and monitor the sensors.

Once all the parts were finally accounted for he tested the rig as a pen plotter. The pen was eventually replaced with the router motor and that ring light PCB seen above was the first thing he milled with it.

[Thanks Justin]

One game controller connects to many consoles

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[Dave Nunez] wanted arcade quality controls when gaming at home. The problem was he couldn’t decide on just one console to target with his build, so he targeted them all. What you see above is a single controller that connects to many different gaming rigs.

He took a simple-is-best approach, keeping the main goal of high-quality inputs at the forefront. To start, he built the face plate out of thick MDF to ensure it wouldn’t flex or bounce as he mashed the buttons. To keep the electronics as simple as possible he soldered connections to actual controller PCBs (well, reproductions of controllers), breaking each out to a separate DB9 connector on the back of the case. These connectors interface with one of the three adapter cables seen to the right. This lets the controller work with NES, SNES, and an Atari 2600 system.

To pull the enclosure together [Dave] designed the rounded corner pieces and cut them out with a CNC mill. These connect with flat MDF to make up the sides. To give it that professional look he filled the joints with Bondo and sanded them smooth before painting.

Hackaday Links: Sunday, April 21st, 2013

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Regular reader and master hacker [Bill Porter] got married. Congratulations [Bill] and [Mara]! The two of them just couldn’t leave their soldering irons at home. The actually swore their vows by soldering together a circuit during the ceremony (blinky wedding dress, el wire tuxedo, and all).

[Kevin] sent in a link to [Red Fathom's] hacked Wacom tablet. It’s the screen from a Wacom-enabled laptop brought back to life with a Teensy and an LVDS interface module.

The Neato XV-11 is able to find its charging station when the batteries run low. [Derek] figured out that you can make a second station using some reflective tape.

If you use your drill a lot you’ll eventually break the rubber thing that holds the key to the chuck. Here’s a way to 3D print a replacement.

[Torxe] put eight floppy drives to use as a polyphonic Arduino-controlled MIDI player. And while we’re on the subject of Arduino controlled projects you should take a look at this web-interface to tell you if the foosball table is being used.

And finally [Th3 Bad Wolf] sent in this link to a milling machine built out of LEGO. It is able to mill floral foam and uses a lathe-like setup for one of the table axes.