Here’s something that may be of interest to all the reprappers, vacuum formers, and other plastic fabbers out there: ultrasonic welding of plastics. If you’ve ever wanted to join two pieces of plastic without melting them together with acetone or screwing them together, [circuitguru] is your guy.

Ultrasonic welder setups are usually reserved for companies that don’t mind spending tens of thousands of dollars on a piece equipment. There are smaller versions made for heat staking - melting plastic pillars into rivets on the work piece – and [circuitguru] was lucky enough a somewhat reasonable price.

Because the heat staking gun was a handheld unit, a rotary tool drill press was put to work. The end result is a relatively inexpensive way to join two plastic parts without screws, glue, or solvents. The bond is pretty strong, too. Check out the video after the break to see [circuitguru] join two pieces of a plastic enclosure and try to tear them apart.

That, dear readers, is the smell of a new Hackspace opening up in Davenport Iowa. It is also the lovely scent of burning plastic. Because how do you celebrate a new Hackerspace? By casting bronze coins of course!

Begin by having a MakerBot extrude plastic coins, then compact the plastic coin in sand to produce a mold. Heat up your bronze in a trashcan furnace and pour it into the mold. The plastic melts away and you’re left with a bronze coin.

There are probably some safety measures and precautions that should be followed as well…

The old saying, “garbage in, garbage out” may need to be re-evaluated. Students at Victoria University of Wellington are developing a machine that recycles old milk jugs, extruding an HDPE plastic filament that can then be fed into a MakerBot for 3D printing.

The process involves grinding the plastic into small pieces, then pressing these through a heater and extruder plate to produce a continuous bead of the proper diameter for the MakerBot. Nichrome wire — the stuff of hair dryers and toasters — forms the heating element, and this must be regulated within a specific temperature range for different plastics. The initial grinder design is hand-cranked, but they are working toward a fully automated system. It appears that the machine could also recycle old MakerBot output, provided the grinder has sufficient torque.

Well, maybe the title is not so true. This “Porsche” GT3‘s construction is a bit unorthodox, the chassis looks to be aluminum tubing, with bicycle tires and other man-powered parts for propulsion. The body is entirely plastic and tape, yeah…gold…foil…tape. Hey, when you really really want to turn someones head.

Regardless, the car even comes complete with working lights, horn, doors, trunk, and lexan windows. Sure it will never go 0 to 60 (yet), but the mileage is amazing! Follow an amusing video of it after the rift.

[via OMGsoysauce]

Many of our cherished computers and consoles from the past have not stood up well over time. It’s not the hardware as much as the color. From Commodores, Apples, to Super Nintendos, the machines have slowly drifted towards a sickly yellow and even brown. The culprit appears to be the fire retardant chemicals used in the plastics. Amiga enthusiasts have spent the last year perfecting a technique that restores the plastic of these machines to its original splendor. Dubbed ‘Retr0brite‘ it’s a gel made from hydrogen peroxide, xanthan gum, glycerine, and ‘Oxy’ style laundry booster. The results are really impressive. If you do start restoring your own machines, caution should be used since it requires strong concentrations of hydrogen peroxide typically employed in bleaching hair.

[via Waxy]

Got 30 minutes for a holiday project and don’t want to get wrangled into some sort of decoupage disaster? Evil Mad Scientist Laboratories can show you just how easy it is to do edge lighting effects. Pictured above are three holiday cards constructed using scored plastic. You can use many different types of clear plastic for this, not just acrylic. The lighting is just an LED on a coincell. Black tape is used to prevent light leaking from the edges. The red and green version above is two stacked layers. This looks like something fun to scale up for a larger project or just to kill some time.

RepRap does not fully assemble copies of itself, but produces the 3D-printed plastic components necessary to assemble another copy. It has also successfully produced other plastic goods like sandals and coat hooks. [Dr. Adrian Bower] is the leader of the RepRap team, and he will be exhibiting its capabilities at this week’s Cheltenham Science Festival.

[via BoingBoing]