Heat-Set Insert Jig Grants Threads to 3D Prints

FDM 3D prints might be coming home this holiday as seasonal ornaments, but with a few tweaks, they may even stand up to the tests of the real world as functional prototypes. Heat-Set inserts are one such tweak that we can drop into a print, and [Kurt] spares no expense at laying down a guide to get us comfortable with these parts. Here, he’s created a drill press adapter and modified his soldering iron to form an insert jig to start melting these parts into his next project.

Heat-set inserts grant us proper screw threads in any thermoplastic. Simply heat them up, stake them into your part, let cool, and: voila–a screw thread that’s firmly embedded into our part. We can load these inserts with clumsy hand tools, but why fumble and bumble with a hot soldering iron when we can adapt our drill press to do most of the tricky fixturing for us? That’s exactly what [Kurt] did here. With a 3D-printed adaptor, he’s letting his drill press (turned off!) hold the soldering iron so that he can use the lever to slowly stake the part into the 3D print. Finally, for no additional charge, [Kurt] turned down his soldering tip to mate cleanly into the insert for a cleaner removal.

We’ve seen adapters like this one before, but it’s never too often to get a reminder of the structural bonus that these parts can add to our 3D prints.

Sable-Machined Slingshot is a Composite Marvel

Armed with an overseas CNC machine retrofitted with custom electronics, [Eric] has taken to wowing us with his suite of home-fabricated slingshots. In a more recent stint, he’s just polished off his Enzo Carbon Fiber Hydra Slingshot, complete with a build log that’s loaded with step-by-step insights.

[Eric’s] build started with a few carbon panels laying dormant in his shop for half a year. After epoxying two of these boards together for added thickness, he machines them down with his retrofitted Sable-2015 “Lunchbox CNC.” His final product accepts a few press-fit inserts, a few more machined ABS edge pieces for aesthetics, and behold: a professional slingshot that’s about as beautiful as it is dangerous.

Although the Sable-2015 CNC machine (made in Taiwan) isn’t a frequent flyer here on Hackaday, it had dozens of proud owners on a few hobby machinist forums that will rave about its wares. We’re proud to see a small-but-sturdy machine that we could carry one-handed be put to such delicate work.

[Eric] could’ve had us with his Lunchbox CNC Instructable, but he’s taken his craftsmanship to the next level by leveraging his homebrew tools and living the bootstrapped-machine-shop narrative. Slingshots don’t land here too often on these pages, but if you’re hungry for another machine monster, have a look at [Dennis the Menace’s] Triple Threat.

Friction Differential Drive is a Laser-Cut Triumph

Here on Hackaday, too often do we turn our heads and gaze at the novelty of 3D printing functional devices. It’s easy to forget that other techniques for assembling functional prototypes exist. Here, [Reuben] nails the aspect of functional prototyping with the laser cutter with a real-world application: a roll-pitch friction differential drive built from just off-the shelf and laser-cut parts!

The centerpiece is held together with friction, where both the order of assembly and the slight wedged edge made from the laser cutter kerf keeps the components from falling apart. Pulleys transfer motion from the would-be motor mounts, where the belts are actually tensioned with a roller bearing mechanism that’s pushed into position. Finally, the friction drive itself is made from roller-blade wheels, where the torque transferred to the plate is driven by just how tightly the top screw is tightened onto the wheels. We’d say that [Reuben] is pushing boundaries with this build–but that’s not true. Rather, he’s using a series of repeatable motifs together to assemble a both beautiful and complex working mechanism.

This design is an old-school wonder from 2012 uncovered from a former Stanford course. The legendary CS235 aimed to teach “unmechanically-minded” roboticists how to build a host of mechanisms in the same spirit as MIT’s How-to-make-almost-Anything class. While CS235 doesn’t exist anymore, don’t fret. [Reuben] kindly posted his best lectures online for the world to enjoy.

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Researchers Squeeze Out a New Breed of Robot Locomotion

Researchers have been playing around with various oddball forms of robot locomotion; surely, we’ve seen it all, haven’t we? Not so! Lucky for us, [researchers at Stanford] are now showing us a new way for robots to literally extrude themselves from point A to point B.

This robot’s particular motion for mechanism involves unwinding itself inside out. From a stationary base, a reel caches meters of the robot’s uninflated polyethylene body, which it deploys by pressurizing. Researchers can make full 3D turns by varying the amount of inflated air in outer control chambers. What’s more, they can place end effectors or even payloads at the tip of the growing end with their position held in place by a cable.

As we can imagine, any robot that can squeeze its way up to 72 meters long can have dozens of applications, and the folks at Stanford have explored a host of nooks and crannies of this space. Along the way, they deploy complex antenna shapes into the air, deliver small payloads, extinguish fires, and squeeze through all sorts of uninviting places such as flytraps and even a bed of nails. We’ve placed a video below the break, but have a look at Ars Technica’s full video suite to get a sense of the sheer variety of applications that they imparted upon their new creation.

Biomimetics tends to get us to cry “gecko feet” or “snake robots” without thinking too hard. But these forms of locomotion that come to mind all seem to derive from the animal kingdom. One key element of this soft robot is that its stationary base and vine-like locomotion both have its roots in the plant kingdom. It’s a testament to just how unexplored this realm may be, and that researchers and robots will continue to develop new ways of artificially “getting around” for years to come.

Thanks for the tip, [Jacob!]

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A Noob’s Guide to McMaster-Carr

For the penny-pinching basement hacker, McMaster-Carr seems like a weird go-to resource for hardware. For one, they’re primarily a B2B company; and, for two, their prices aren’t cheap. Yet their name is ubiquitous among the hacker community. Why? Despite the price, something makes them too useful to ignore by everyday DIY enthusiasts. Those of us who’ve already been enlightened by the McMaster-Carr can design wonders with a vocabulary of parts just one day away at the click of a button.

Today, this article is for those of us who have yet to receive that enlightenment. When used wisely, this source of mechanical everything brings us a world of fast parts at our fingertips. When used poorly, we find nothing but overpriced stock components in oversized shipping boxes.

Since we, the McMaster-Carr sages, are forever doomed to stuff our desk drawers with those characteristic yellow baggies till the end of time, we thought we’d give an intro to the noobs that are just beginning to flex their muscles with this almighty resource. Grab another cup of coffee as we take you on a tour of the good and good-grievances of McMaster-Carr.

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2017’s VCF West is Another Beloved Trip Down Memory Lane

This past weekend, another smashing round of the Vintage Computer Festival was held at the Computer History Museum in Mountainview. As always, VCF West gathers the sages and lords of vintage computers onto a common ground to talk old-school hardware. It also draws in a collection of unique artifacts, many of which either still work, have been brought back to life, or have otherwise been reincarnated through a modern means. [Bil Herd] and I dropped in to join the crowd, and I snagged a few pics of some new faces and pieces that have been added to the experience since last year.

[Foone’s] Digital Media Archiving

Up first on our bucket list was [Foone], a librarian of digital media archiving. Outside of VCF, he runs a digital media backup gig to help folks backup their niche, often-failing, disk formats into something more modern. His drive for doing this backup features a special “reread” capability, where the file is actually reread dozens of time to validate that the right information was pulled from it.

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A Case for the Desktop Vinyl Cutter

As far as desktop workbench fab tools go, it’s too easy to let 3D printers keep stealing the spotlight. I mean, who doesn’t appreciate that mechatronic “buzz” as our printer squirts a 3D CAD model into plastic life? While the 3D printer can take up a corner of my workbench, there’s still plenty of room for other desktop rapid-prototyping gadgets.

Today, I’d like to shed some light on vinyl cutters. Sure, we can start with stickers and perhaps even jumpstart an after-hours Etsy-mart, but there’s a host of other benefits besides just vinyl cutting. In fact, vinyl cutters might just be the unsung heroes of research in folding and papercraft.

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