Cutting Glass With CNC

Breaking a pane of glass in half is easy – just score it, break it, and after practicing a few times, you’ll eventually get it right. What about cuts that are impossible with a normal glass cutter, like radiused corners and holes? For that, you’ll need CNC. Yes, you can cut glass on a CNC machine. All you need is a diamond burr or glass drilling bit, high speeds, low feeds, and lots and lots of coolant.

Cutting glass on a CNC machine doesn’t require any spectacularly specialist equipment. [Peter] is using an $800 Chinese mini CNC engraver for this project, but that’s not the only tool that was required. A fixture for holding a glass plate was also needed, but [Peter] quickly fabricated one out of acrylic.

Cutting glass with a CNC is something we’ve seen before. [Ben Krasnow] has been using diamond burrs, high speeds, low feeds, and lots of coolant to cut mirrors so expensive you don’t even want to guess.

While [Peter] isn’t getting the perfect finish [Ben] got a few years ago, he’s still milling holes and slots in glass. He’s wondering if it could be possible to mill an aspheric lens using this technique and a special spherical burr, something that would be very interesting to see, and could be a pretty good way to rough out telescope blanks.

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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Hackaday Links: October 12, 2014

Remember in the late 90s and early 2000s when everything had blue LEDs in them? Blinding blue LEDs that lit up a dark room like a Christmas tree? Nobel prize. There’s a good /r/askscience thread on why this is so important. The TL;DR is that it’s tough to put a p-type layer on gallium nitride.

Have a Segway and you’re a member of the 501st? Here’s your Halloween costume. It’s a model of the Aratech 74-Z speeder bike, most famously seen careening into the side of trees on the forest moon of Endor.

[Andrew] needed something to do and machined an iPhone 5 out of a block of aluminum. Here’s the video of icon labels being engraved. The machine is a Denford Triac with a six station auto tool changer. He’s running Mach3, and according to him everything – including the correct tooling – cost far too much money.

Another [Andrew] was working the LEGO booth at Maker Faire New York and has finally gotten his LEGO Mindstorms Minecraft Creeper build written up. Yes, it’s probably smarter than your average Minecraft Creeper, and this one also blows up. He also had a physical version of the classic video game from 1979, Lunar Lander. Both are extremely awesome builds, and a great way to attract kids of all ages to a booth.

titanium[Wilfred] was testing a titanium 3D printer at work and was looking for something to print. The skull ‘n wrenches was a suitable candidate, and the results are fantastic. From [Wilfred]: “Just out of the printer the logo looks amazing because it isn’t oxidized yet (inside the printer is an Argon atmosphere) Then the logo moves to an oven to anneal the stress made by the laser. But then it gets brown and ugly. After sandblasting we get a lovely bluish color as you can see in the last picture.”

The folks at Lulzbot/Aleph Objects are experimenting with their yet-to-be-released printer, codenamed ‘Begonia’. They’re 2D printing, strangely enough, and for only using a standard Bic pen, the results look great.

Everyone is going crazy over the ESP8266 UART to WiFi module. There’s another module that came up on Seeed recently, the EMW3162. It’s an ARM Cortex M3 with plenty of Flash, has 802.11 b/g/n, and it’s $8.50 USD. Out of stock, of course.

Joe Grand Talks Deconstructing Circuit Boards

With the exception of [Eric Evenchick], the Hackaday crew are safely back from Defcon and not missing in the desert. This means we can really start rolling out all the stuff we saw this weekend, beginning with an interview with [Joe Grand], creator of the JTAGulator, early member of l0pht, and generally awesome dude.

The focus of [Joe]’s many talks this year was reverse engineering circuit boards. Most of these techniques involved fairly low-tech methods to peel apart circuit boards one layer at a time: sandpaper and milling machines are the simplest techniques, but [Joe] is also using some significantly more uncommon methods. Lapping machines get a mention, as do acoustic microscopy, CAT scans, and x-rays. [Joe]’s Defcon talk isn’t up on the intertubes yet, but his BSides talk about techniques that didn’t work is available.

In case you forgot, [Joe] is also a judge for a little contest we’re running, and we asked what he’s looking for in a truly spaceworthy entry. [Joe]’s looking for projects with a lot of effort put into them. Don’t get us wrong, project that require no effort can be extremely popular, but documentation is king. [Joe] thinks well documented projects are evidence project creators are building something because they want to build it, and not because they want to win a prize. That’s intrinsic motivation, kiddies. Learn it.

Copying objects in 3D

photocopier

[Pulse 9] sent in a very interesting project he just finished up at an internship. It’s a 3D photocopier that scans an object and then mills said object into floral foam.

The copier is made out of material [Pulse] found sitting around – PVC, drawer slides for the X and Y axes, acrylic for the structure, and broken printer parts for the Z axis.

To scan an object, [Pulse] puts an object down on the bed and scans it with a laser and webcam. The images recorded on the camera are fed into MATLAB. The output from MATLAB is sent over serial to a custom board containing a PIC18F4620 that controls the axis motors. The spindle for this floral foam router is a simple drill; one layer at a time, the drill mills out the unneeded foam which can be sucked up by a vacuum when the object is complete.

Below you’ll find [Pulse]’s demo of his photocopier and a piece the local news did on the project. If anyone is willing to translate that story, feel free to do so in the comments.

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Milled water bottle rocket launcher pushes plastic containers to their limit

water-bottle-rocket-launcher

Building this launcher is simple if you already have a mill. It does a remarkable job of pressurizing and launching soda bottles which are partially filled with water. The main component of this is a triple-gasket stopper with a quick release.

The problem with a lot of these water bottle rocket projects is that they leak where the bottle meets the launcher. In most cases this is a good thing as it’s almost impossible to build up enough pressure to cause the bottle to fail. This system has no such built-in safety mechanism, which is why the test launch below is conducted from a safe distance. After seating the partially filled bottle on the launch platform it’s pressurized to around 100 PSI at which point a yank on the string lets it fly.

Most of the time we look on these as casual projects. But we figure this one is much more suited for a rocket club or hackerspace event.

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Machining beer can solder stencils

soda-can-solder-stencils

This is a solder paste stencil machined from a beer can. [Simon Ludborzs] spent quite a bit of time dialing in his process to get to this point. Note the nice crisp edges of the openings. That’s a big change from his first attempt.

When looking for a way to make his own stencils he considered two options: plastic and aluminum. He produced both (more about the plastic stencil and his reflow process is discussed in this post). Plastic is a bit easier to work with since it lays flat. But it proves to be too thick. After applying paste with a squeegee there’s way too much solder on the pads. Aluminum beverage can walls are much thinner, depositing less paste.

We’ve seen soda cans used in the past, but they were produced through an etching process. [Simon] cut these holes using a CNC mill. This required a bit of futzing to figure out the right settings. For instance, he used Altium to produce CAM files from his circuit design. But the program is set up to mill the outside of traces, resulting in openings that are too large. He fixed this by setting the pasted expansion rule in the program to a negative value. The other advantage to using a mill is that he can cut precision tooling holes to ensure proper alignment. You can see them in the upper corners of this image.