Machine Metal With Electricity: An EDM Attachment For 3D Printers

[SuperUnknown] has revealed a secret project he’s been working on. He’s cooked up an EDM attachment for 3D printers, or any CNC machine for that matter. Electrical Discharge Machining (EDM) is a method of using sparks to machine metal. EDM isn’t a new technology, in fact commercial machines have been around since the 1960’s. If you’ve ever had an arc scar up your multimeter probes, you’ve unwittingly done a bit of EDM.

The theory behind EDM is simple: High voltage between the tool and workpiece causes sparks to jump between them. Each spark erodes the workpiece (and the tool). Big EDM machines perform their magic in a liquid which acts as both a dielectric and a flushing medium. This liquid can be anything from deionzed tap water to specially formulated oil. [SuperUnknown] is using good old-fashioned tap water.

edm-roughAs you can imagine, a single spark won’t erode much metal. EDM machines fire tens of thousands of times per second. The exact frequencies, voltages, and currents are secrets the machine manufacturers keep close to their chests. [SuperUnknown] is zeroing in on 65 volts at 2 amps, running at 35 kHz. He’s made some great progress, gouging into hardened files, removing broken taps from brass, and even eroding the impression of a coin in steel.

While we’d love to say this is a free open source project, [superUnknown] needs to pay the bills. He’s going with crowdsourced funding. No, not another Kickstarter. This project is taking a different route. The videos of the machine will be uploaded to YouTube and visible to [superUnknown’s] Patreon supporters. They will also be available for rent using YouTube’s new rental system. [SuperUnknown] has pledged to figure out a way to make the content available for starving college students and others with limited incomes.

Based upon his previous adventures with lil’ screwy, his homemade 100 ton press, and various other projects on the Arduino verses Evil YouTube channel, we think [superUnkown] has a pretty good chance of making home EDM work. Click past the break to see two videos of the 3D printer EDM toolhead in action. We should mention that [SuperUnknown] is rather colorful with his dialogue, so make sure you’re using headphones if you’re at work.

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Hackaday Prize Entry: Python Powered Scientific Instrumentation

A common theme in The Hackaday Prize and in general is tools to make more tools. There are a lot of people out there trying to make the next Bus Pirate, and simply measuring things is the first step towards automating a house or creating the next great blinkey invention.

In what is probably the most capable measurement system in the running for this year’s Hackaday Prize, [jithin] is working on a Python Powered Scientific Instrumentation Tool. It’s a microcontroller-powered box containing just about every imaginable benchtop electronics tool, from constant current supplies, LCR meters, waveform generators, frequency counters, and a logic analyzer.

This project is stuffed to the gills with just about every electronic tool imaginable; there are programmable gain amplifiers, voltage references, DACs and constant current sources, opamps and comparators, all connected to a bunch of banana jacks. All of these components are tied up in a nifty Python framework, allowing a bunch of measurements to be taken by a single box.

If that’s not enough, [jithin] is also working on wireless extension nodes for this box to get data from multiple acquisition points where wires would be unfeasible. This feature uses a NRF24L01+ radio module; it’s more than enough bandwidth for a lot of sensors, and there’s enough space all the wireless sensors you would ever need.

The 2015 Hackaday Prize is sponsored by:

Hackaday Prize Entry: The MultiSpork

If you’re working on a mobile project – a robot, something outside, or even your car – you don’t want to bring an oscilloscope, logic analyzer, signal generator, or any other piece of equipment that should stay on the bench. For his Hackaday Prize Entry, [Pierce Nichols] is working on the electronic equivalent of a Leatherman: something small and portable that also does just enough to get by in a pinch.

The MultiSpork, as [Pierce] calls his device, is a single WiFi enabled board that’s completely portable. With the addition of a $50 Android tablet, it’s very close to a complete electronics lab in a box.

The heart of the MultiSpork is a new chip from Maxim, the MAX 11300. This chip has 20 pins that can be used as a 12-bit ADC, a 12-bit DAC, or as GPIOs. it’s a logic analyzer, signal generator, oscilloscope, and a Bus Pirate in a single chip. As far as the rest of the board goes, [Pierce] is forgoing any notion of a hardware freeze and changing the Atmel microcontroller over to a TI CC3200 chip that will be coming out soon.

[Pierce] put together a short video describing the MultiSpork; you can check that out below.

The 2015 Hackaday Prize is sponsored by:

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Workbench Eye Candy from Around the World

The workbench. We’re always looking for ways to make the most out of the tools we have, planning our next equipment purchase, all the while dealing with the (sometimes limited) space we’re allotted. Well, before you go off and build your perfect electronics lab, this forum thread on the EEVblog should be your first stop for some extended drooling research.

You’ll find a great discussion about everything from workbench height, size, organization, shelf depth, and lighting, with tons of photos to go with it. You’ll also get a chance to peek at how other people have set up their labs. (Warning, the thread is over 1000 posts long, so you might want to go grab a snack.)

We should stop for a moment and give a special note to those of you who are just beginning in electronics. You do not need to have a fancy setup to get started. Most of these well equipped labs is the result of being in the industry for years and years. Trust us when we say, you can get started in electronics with nothing more than your kitchen table, a few tools, and a few parts. All of us started that way. So don’t let anything you see here dissuade you from jumping in. As proof, we’ve seen some amazingly professional work being done with the most bare-bones of tools (and conversely, we seen some head-scratching projects by people with +$10,000 of dollars of equipment on their desk.)

Here’s some links that you might find handy when setting up a lab. [Kenneth Finnegan] has a great blog post on how his lab is equipped. And [Dave Jones] of the EEVblog has a video covering the basics. One of the beautiful things about getting started in electronics is that used and vintage equipment can really stretch your dollars when setting up a lab. So if you’re looking into some vintage gear, head on over to the Emperor of Test Equipment. Of course no thread about workbenches would be complete with out a mention of Jim Williams’ desk. We’ll leave the discussion about workbench cleanliness for the comments.

Massive Wood Joints With Chainsaw Mortiser

mortise-tenonOne common joinery method used in wood working is the mortise and tenon. A mortise is basically a hole in a piece of wood and the tenon is another piece of wood cut to tightly fit in that hole. The tenon is usually secured in place with either glue or a wooden pin or wedge.

The folks over at [WayOutWest] were building a fence and needed a way to cut a bunch of mortises in 4×4 inch posts to accept 2×6 inch rails. Although they had a chainsaw, trying to cut a mortise with it by hand turned out to be super dangerous because the chainsaw would kick up every time the tip of the blade touched the wood. The team had some parts kicking around so they made a fixture to hold the chainsaw as it is plunged into the 4×4’s.

The contraption’s frame is made from an old scaffolding stand and the slides are just pipes inside of pipes. The chainsaw is bolted to the slide and a lever moves it forward and back. A second lever moves the piece of wood getting mortised up and down so that the mortise can be cut to any width. This is a pretty ingenious build that only cost a little effort and will end up saving a bunch of time mortising countless fence posts.

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3D Printed Pogo Pin Programmer

The new hotness for Internet of Things hardware is the ESP8266. Alone it can connect to a WiFi network, but it doesn’t really have a lot of output options. Paired with an ATMega, and you really have something. That’s the philosophy behind the WIOT board, and when [Chris] was assembling these boards, he needed a way to flash firmware. The board has an unpopulated ISP header from the assembler, so pogo pins are the answer. How do you make a pogo pin jig? With a 3D printer, of course.

The ISP header wasn’t populated to give the board a slim profile, but this means a jig of sorts would be needed to program the WIOT. The first attempt was buying a few pogo pin adapters from Tindie, but this was terribly uncomfortable to hold while the board was being programmed.

To fix this problem, a small clip device was rigged up, printed out, and used for programming. Interestingly, this clip has a very deep throat, and a few holes used for bolting on a separate programmer. This shows a lot of forward thinking: the programmer can be reused for different boards with completely different layouts and programmers. If the next revision of the WIOT needs a JTAG header to program the micro, the problem of programming it is already covered.

Building A 20 Inch Disk Sander

A small disk sander is a useful and cheap addition to the shop. For about $100, you can buy a cheap combination 6″ disk/belt sander that’s extremely useful. The size and cost of power tools does not scale linearly, and if you want a big disk sander you might as well make your own.

The motor for this build is a 1kW single phase motor pulled from a floor polisher found in the trash. That’s enough to push a sanding disk around, but when you get to tools this large, you need a good base, good tilt mechanism, and everything should be extremely heavy.

This build meets all those requirements while still using mostly recycled components. The work table is actually made of three pieces of recycled aluminum epoxied together. Yes, you should cringe at this, but it actually makes a little bit of sense: thinner pieces can be cut on a table saw, and if you’re extremely careful during the glue-up, you can cut the mitre slot without a mill. This frame attaches to a frame made from aluminum extrusion and filled with a homebrew epoxy granite mix. Remember, heavy is better here.

In keeping with making a huge disk sander out of stuff pulled out of the trash, the trunnions and motor hub were cast out of aluminum melted in an old propane tank furnace. Once these were cleaned up, a disk was mounted on the hub and trued up in the most unsafe manner possible.

With a few additions including a machined mitre gauge, dust collector, and legs made out of wood that’s far too pretty for a simple shop tool, this huge assemblage of trash turned out to be a great sander. You can see a few videos of it below.

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