Author: George Graves

59 Articles

3D Miniature Chess Pieces Made With A Laser Cutter

June 14, 2015 by 6 Comments

When you think of laser cutters, you generally don’t think of 3d parts. Well, at least not without using something like glue, nuts and bolts, or tabs and slots to hold multiple parts together. [Steve Kranz] shows you how to make these very tiny 3D chess pieces by making 2 passes at right angles to thick acrylic. The first pass cuts one side’s profile, then the part is rotated 90 degrees and a second pass is cut, giving the part more of a “real” 3D look, rather than something cut out of a flat sheet. If you’re having a hard time imagining how it works, his pictures do a great job of explaining the process. He even added some engraving to give the chess pieces for a selective frosted look. We think it’s a cool idea, and well executed too!

But that got us to thinking (always dangerous) that we’ve seen rotary attachments for laser cutters, but they are mainly for etching cylindrical objects like champagne flutes and beer bottle. What if you added a rotating “3rd” axis to a laser cutter that could hold a block of material and rotate it while being cut? (Much like a traditional 4th Axis on a CNC machine). Would the material also need to be raised and lowered to keep the laser focused? Surely software that is aimed at 3D CNC would be needed, something like Mach3 perhaps. A quick Google search show that there are some industrial machines that more-or-less do 3D laser cutting, but if you, or someone you know of, has attached a 3rd axis to a desktop laser, let us know in the comments, we would love to see it.

(via Adafruit)

Hanging Onto The World’s Greatest Piggyback Ride.

June 12, 2015 by 27 Comments

We were really sad to see NASA retire the Space Shuttle. Even though it’s being replaced with some new and exciting hardware, we have fond memories of the Shuttle program. The good news is that a lot of the old hardware can now be seen up close and personal. [Brady Haran] recently took a video tour of one of the iconic pieces of hardware from the Shuttle program, the Shuttle Carrier N905NA.

NASA purchased the Boeing 747-100 in 1974 from American Airlines, and by 1976 the jumbo jet was put on a strict diet in preparations to carry the shuttle on it’s back for transportation and initial testing. She was stripped of her interior (all but few first class seats), sound deadening, air conditioning, and baggage compartment. Vertical fins on the tail were added for yaw stability, and the four Pratt and Whitney turbofans were upgraded to more powerful units. The fuselage was strengthened, and mounting points for the shuttle added. Even with all the weight savings, it severely limited the 747’s range from about 5000 miles to about 1000 miles while the orbiter was on it’s back. The aircraft was retired from service after ferrying the Shuttles to their final destinations in 2012.

In the video after the break, you can take a short tour of the N905NA at the Johnson Space Center in Houston where they are preparing it for public display. Visitors will be able to tour the 747 (with exhibits inside the fuselage), and a very accurate mock-up of the shuttle that sits atop.
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These Are The Droid Controllers You’ve Been Looking For

June 8, 2015 by 34 Comments

When I was in the 4th grade our teacher announced that we had a special guest visiting us from somewhere “Far, far away…” As we piled out of the classroom and into to the courtyard, my jaw hit the floor – It was R2D2! The droid started to move around, and made all the noises like the movie. I couldn’t believe what I was seeing. R2D2 was real, and he was right in front of me! (My young mind made the conclusion that if R2D2 was real, then all of Star Wars was real.) I had to turn around to see my friends’ reactions. Unfortunately, it’s at that moment, I saw a middle-aged man, holding a RC transmitter, with antenna extended, standing in the background operating the controls. Sigh. R2 wasn’t real – it’s just a remote-controlled robot. My dreams of becoming a Jedi were forever crushed.

[Chris James] of the R2 Builders Club has been working hard to make a pair of “Stealth RC” controllers to help keep the magic of R2D2 intact.  These dual joystick, 3D printed, hand-held units can be easily hidden in the palm of your hand, or the front pockets of a loose jacket while you operate them. Loaded with features, these tiny controllers use XBee radios to talk to a receiver and custom PCB inside the droid, that in turn, can then control dozens of servos, motors, sound playback and more. Because some R2D2 builds will have dozens and dozens of functions, rather than have a button for each one, [Chris] has programmed in gesture controls in to the unit, so that two controllers and can control several dozen preprogrammed actions. [Chris] hasn’t finalized the design just yet – he still calls it a “beta” build, but so far his documentation is outstanding (PDF) – some of the best we’ve seen.

You can learn more about the R2 Builders Club and the controllers in the video after the break

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Lasersaur That Cuts 1/2″ Plywood And 10mm Acrylic (Pew-Pew)

June 4, 2015 by 54 Comments

Remember when building your own 3D printer was a big deal? We’re starting to think that building your own laser cutter might be the next hot topic.

Boasting a 16,000 square-foot facility, the Dallas Makerspace is an impressive collaboration of local artists, engineers, makers, and thinkers. Recently they embarked on building a serious laser cutting machine. They chose to go with the an open-hardware design rather than buying an off-the-shelf unit. What they built is based on the Lasersaur plans. (Another popular open-source build is the buildlog.net unit.)

They ended up with a huge 24″ by 48″ cutting bed and with a laser tube rated for 100 watts continuous output. It can cut 1/2″ plywood and 10mm acrylic with ease. The entire machine is built from 20mm Misumi aluminum t-slot extrusions, making more like a giant erector set then a commercial built machine. We hadn’t seen too many of the Lasersaur builds out in the wild, so we thought you might like to see one too.

Now, before you start ordering parts to build your own, you should know that a top of the line build like this will run you about $7-10k. But by comparison if you were to go with something with the same cutting area and power, you’d be looking at something like the “Epilog Fusion 40” at a whopping $40k. With that said, we expect to see more budget laser cutter builds. Cost can be cut dramatically when you go for a smaller machine, with less cutting area, and less power. With that, you can use less expensive steppers, drivers, and frame. We suspect a little as $700 for a smart shopper could yield a very respectable laser cutter.

If you’re interested in learning more about the Dallas Makerspace, we took a video tour back in early 2014.

Ultrasonic Misting Vapor Polisher For 3D Printed Parts

May 16, 2015 by 32 Comments

If you’ve ever seen 3D printed parts form an extrusion type printer, one of the first things you’ll notice is the texture. It’s caused by the printer laying down its plastic layer after layer. This surface texture isn’t always desirable, so people have found a few ways to smooth the 3D printed part out. For example if you are using ABS, you can rinse or “paint” the part with acetone. Another method of smoothing is heat up some acetone in a container, and let the acetone vapors do work to smooth the finished part.

[Mike] from engineerdog.com thinks he may have found a more elegant solution using an inexpensive ultrasonic humidifier you can buy online for about $40 USD. This room humidifier uses a piezoelectric transducer that can vibrate liquids at a high frequency to produce a mist. [Mike] removed the transducer and electronics from the humidifier and mounted it into a paint can.  This is where the acetone is stored, and turned into a vapor by the transducer. An aquarium pump is used to transfer the highly concentrated vapors into the polishing chamber (an extra large pickle jar.) He added a spring loaded, electrical timer (the kind you might find in the bathroom at an office building) to make his vapor polisher as easy to use as a microwave oven.

[Mike] concludes his post with some strength testing of parts before and after acetone treatment, and was surprised to find that the parts were weaker after the treatment.  You can read more about that on his blog and see a video of the vapor polisher after the break.

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Hacking The United States Postal Service (Kinda)

May 15, 2015 by 24 Comments

The United States Postal Service (USPS) is fixture of American life with its roots going back to colonial times. It operates the largest civilian vehicle fleet in the world, delivering about half a billion pieces of mail a day. As with any system of that size it’s always interesting to peek and poke at to see how it works. Unfortunately, it’s not as fun to hack as the phone system once was, but that didn’t stop some hackers pranksters from giving it a go.

So how do you “hack” the mail? Simple, by testing its own rules. The folks at [Improbable Research] did just that and some of the results were interesting enough that we thought we would share them with you. They started with testing valuable items to see how honest USPS employees would be. First they attached a $20 bill to a post card. Yep, it showed up just 4 days later, and the money was still there. So they decided to see if sentimental items, that normally would be refused by the postal service, might skate through.  They were able to send both an un-boxed single rose, and a human tooth (in a clear plastic box) without issue. Both arrived just fine, despite the rule that human remains are not allowed to be shipped via USPS.  We’ll let you read some of the other items they tried.

So the next time you’re in Hawaii, forget about sending that generic, boring post card back home. Instead, slap some stamps on a coconut to let your friends know exactly how much fun you’re having.

With that said, we wouldn’t be doing our job looking out for our readers if we didn’t mention that before you try anything too outlandish, you can be fined for abuse of the postal system, even as a recipient. There was a fair amount of fallout when those guys sent a camera through the mail. Have fun, but not at someone else’s expense.

Portable Workbench Is Solid And Space Saving

May 8, 2015 by 28 Comments

Last week we covered the topic of electronic work benches. But we know that there’s more to life than soldering irons and tiny components. Sometimes to pull off a hack, you need to get your hands dirty, and get some sawdust in your hair. If you’re limited on space, or need to be able to move to different locations quickly, this shop workbench may just be what you’re looking for.

First, let us preface that this project is not open source. Now before you “boo!” too loudly, the designer [Ron Paulk] only charges $10 for the plans. We think that is a small price to pay for how much though has gone into the design. But hey, if you’re a bit crafty, we bet you could easily reverse engineer the build just from the pictures alone. Personally, we think there are times when it’s a good thing to support a project like this.

The basic design allows the workbench to be very rigid, but light weight. And if you don’t have room for it to be permanently set up, it tears down and stores away nicely. It seems like the plans are well done, but if you need a bit more guidance, there is also a 15 part video series that will guide you along the way (here is the youtube playlist.) Also, there is an overview video after the break.  So what are you waiting for?  Go out and make something!

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