A CNC You Could Pop-Rivet Together

You have to be careful with CNC; it’s a slippery slope. You start off one day just trying out a 3D printer, and it’s not six months before you’re elbow deep in a discarded Xerox looking for stepper motors and precision rods. This is evident from [Dan] and his brother’s angle aluminum CNC build.

Five or six years ago they teamed up to build one of those MDF CNC routers. It was okay, but really only cut foam. So they moved on to a Rostock 3D printer. This worked much better, and for a few years it sated them. However, recently, they just weren’t getting what they needed from it. The 3D printer had taught them a lot of new things, 3D modeling, the ins of running a CNC, and a whole slew of making skills. They decided to tackle the CNC again.

The new design is simple and cheap. The frame is angle aluminum held together with screws. The motion components are all 3D printed. The spindle is just an import rotary tool. It’s a simple design, and it should serve them well for light, low precision cuts. We suspect that it’s not the last machine the pair will build. You can see it in action in the video after the break.

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Virtualizing Around The FCC’s Firmware Modification Rules

Last year, the FCC introduced new regulations requiring router manufacturers to implement software security to limit the power output in specific 5GHz bands. Government regulations follow the laws of unintended consequences, and the immediate fear surrounding this new directive from the FCC was that WiFi router manufacturers would make the easiest engineering decision. These fears came true early this year when it was revealed a large router manufacturer was not following the FCC regulations to the letter by limiting the output of the radio module itself, but instead locking down the entire router.

The FCC’s rules regarding the power output of 5GHz routers was never a serious concern; the FCC is, after all, directed to keep the spectrum clean, and can force manufacturers to limit the power output of the wireless devices. The problem comes from how manufacturers implement this regulation – the easiest solution to prevent users from modifying the output of the radio module will always be preventing users from modifying the entire router. Developers don’t like it, the smart users are horrified, and even the FCC is a little flustered with the unintended consequences of its regulation.

While the easiest solution to preventing the modification of a radio module is to prevent modification to the entire router, there is another way. The folks at Imagination Technologies have come up with a virtualization scheme that allows router manufacturers to lock down the radio module per the FCC directive while still allowing the use of Open Source router firmware like OpenWrt.

A demonstration of the capabilities of this next-generation router comes from the prpl Security Working Group and uses MIPS Warrior CPUs to create multiple trusted environments. The control of the router can be handled by one secure environment, while the rest of the router firmware – OpenWrt included – can be run in an environment more conducive to Open Source firmware.

The demo of a compartmentalized, virtualized router uses a dev kit consisting of a dual-core MIPS P5600 CPU running at 1GHz, and a Realtek RTL8192 WiFi adapter plugged into the USB port. The driver for the WiFi adapter runs under a secure hypervisor, making it secure enough to pass the FCC’s muster.

This build wouldn’t be possible without hardware virtualization in microprocessors and microcontrollers. Imagination Technologies has been working on this for a while, and only a few years ago demonstrated a PIC32 with baked in virtualization.

In the video below, Imagination Technologies demonstrates a MIPS board running three virtual machines. The first machine is running OpenWrt, the second is running a WiFi driver, and the third is running third-party applications. Crashing one machine doesn’t bring down the others, and the WiFi driver is locked away in a secure environment in accordance with the FCC regulations.

While it’s hard to imagine a router based on a MIPS board that would be cheaper than the already inexpensive router SoCs found in today’s routers, this method of secure virtualization is the best way to give consumers what they deserve: an open source option for all their devices.

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Shaper Tools Will Blow Your Mind

Have you ever wanted to own a full-sized ShopBot? What if some geniuses somewhere made a tool the size of a coffee maker that had the same capabilities? Does an augmented reality, real-time feedback, interactive, handheld CNC router that can make objects ranging in size from a pillbox to an entire conference room table sound like a thing that even exists? It didn’t to me at first, but then I visited the Shaper Tools office in San Francisco and they blew my mind with their flagship tool, Shaper Origin.

This table and the spool holder sitting on it was made with a machine the size of a coffee maker.
This table and the spool holder sitting on it was made with a machine the size of a coffee maker.

It’s impossible for me not to sound like a fan boy. Using Shaper Origin was one of those experiences where you just don’t know what to say afterwards. This is what the future looks like.

I’ve used a lot of CNC tools in my life, from my first home-built CNC conversion, to 1980s monstrosities that ran off the floppy kind of floppy disks, and all the way over to brand new state-of-the-art vertical machining centers. I had to shake a lot of that knowledge off when they demoed the device to me.

Origin is a CNC router built into the form factor of a normal wood router. The router knows where it is on the work piece. You tell it where on the piece you would like to cut out a shape, drill a hole, or make a pocket. It tells you where to go, but as you move it keeps the cutting bit precisely on the path with its three axes of control.

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That’s No Moon – That’s a Bamboo Death Star

At first glance, [Frank Howarth]’s turned bamboo Death Star seems like a straight woodworking project. No Arduino controlled lights, no Raspberry Pi for audio clips of an X-wing attack or escaping TIE fighter. In other words: where’s the hack?

It’s a freaking bamboo Death Star!

If that’s not enough for you, check out the pattern on the surface of the finished model. That’s not painted on – those are the layers of the laminated bamboo lumber used to create the rings [Frank] used to form the structure. After lots of turning, sanding and polishing, the characteristic vascular bundles of the bamboo create light and dark panels for a convincing effect of the Death Star’s surface detail. And although we like the natural finish, we can imagine a darker stain might have really made the details pop and made for an effect closer to the original.

Still not hackish enough? Then feast your eyes on [Frank]’s shop. It’s a cavernous space with high ceilings, tons of natural light, and seemingly every woodworking machine known to man. While the lathe and tablesaw do a lot of the work for this build, the drool-worthy CNC router sees important duty in the creation of the multiple jigs needed for the build, and for making the cutout for the superlaser, in what must have been a tense moment.

Bamboo is an incredible material, whether for fun builds like this or for more structural uses, like a bamboo bike. All this bamboo goodness puts us in the mood to call on [Gerrit Coetzee] for a new installment on his “Materials You Should Know” series.

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FCC Locks Down Router Firmware

For years, we have been graced with consumer electronics that run some form of Linux, have a serial port on the circuit board somewhere, and are able to be upgraded through official and unofficial means. That digital picture frame you got for Christmas in 2007 and forgot to regift in 2008? That’s a computer, and it would make a wonderful Twitter feed display. Your old Linksys WRT54G router? You can make a robotic lawnmower out of that thing. The ability to modify the firmware of consumer electronics is the cornerstone of Hackaday’s editorial prerogative. Now that right we have all enjoyed is in jeopardy, thanks to regulations from the FCC and laziness from router manufacturers.
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DIY Shapeoko 3 Enclosure

Setting up a desktop CNC brings along two additional problems that need to be resolved – noise and dust. [Nick] upgraded from a Shapeoko2 to the Shapeoko3 and decided to build a fresh dust and noise proof enclosure for his CNC , and it turned out way better than he had anticipated.

When trying to build something like this, aluminium extrusions seem like the obvious choice for the structure. Instead, he opted for low-cost steel frame shelving units. The 3mm thick steel frame results in a nice rigid structure. The top and bottom were lined with 18mm thick MDF panels. For the two sides and back, he choose 60mm noise dampening polyurethane foam lined with 6mm MDF on both sides, and held together with spray adhesive and tight friction fit in the frame.

The frame was a tad shallower and caused the spindle of the Shapeoko3 to stick out the front. To take care of this, he installed an additional aluminium frame to increase the depth of the enclosure. This also gave him a nice front surface on which to mount the 10mm thick polycarbonate doors. The doors have magnetic latches to hold them close, and an intentional gap at the top allows air to enter inside the enclosure. A 3D printed outlet port was fixed to the side wall, where he can attach the vacuum hose for dust collection. The final step was to add a pair of industrial door handles and a bank of blue LED strip lights inside the enclosure for illumination.

It’s a simple build, but well executed and something that is essential to keep the shop clean and dampen noise.