Solar-powered CNC Woodburning

December 28, 2011 by Brian Benchoff 19 Comments

[Johnie] built himself a CNC woodburner powered by the sun. Like the solar 3D printer we saw last summer, [Johnie]’s build uses a giant Fresnel lens to focus sunlight onto a piece of wood. To get some control out of his build, a 2-axis bed was made from scrounged and junked parts.

The lens in [Johnie]’s build looks to be about a foot square – more than hot enough to burn a few holes in things from our experience. The bed (hopefully) gets around this problem by being built entirely out of clear acrylic. The idea behind the acrylic bed is that the focused light will pass through harmlessly, and not melt the entire thing.

Now that we think about it, we couldn’t come up with a better project to enter in the Buildlounge laser cutter contest. For everybody else working on their laser cutter projects, the deadline is January 1st. Better get those wrenches out and irons hot, because we’ve seen a few awesome projects for the Buildlounge build off already.

MAMEing A CNC Router

December 22, 2011 by Brian Benchoff 31 Comments

[Ed] is pretty old school. He loves the functionality of old industrial shop tools that have their own dedicated systems. With huge candy-like buttons, who wouldn’t? [Ed] decided to replicate this aesthetic by building a MAME controller for his Mach3 controlled router.

[Ed] had a bunch of MAME buttons and joysticks sitting around from a forgotten project. With his vinyl plotter, it was relatively easy to make a very nice looking control panel. To connect the buttons to the Mach3 computer, a disused I-Pac was brought into the mix. The I-Pac reads the state of the buttons and sends keyboard codes over USB to the computer.

Because the very popular Mach3 CNC software responds to hotkeys, it was very simple to make the buttons do as they say. [Ed] has full control over the X, Y, and Z axes as well as the spindle speed. It seems like this would be interesting to do some ‘free form’ CNC work on [Ed]’s router.

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Playing With Routers, Vinyl And Music Concrete

December 19, 2011 by Brian Benchoff 40 Comments

When Danish musicians Vinyl Terror and Horror visited [Daniel] and his CNC router at EMS in Sweden, things were sure to get interesting. The band uses heavily modified record players and modified vinyl records to produce strange soundscapes. During their time at EMS, Vinyl Terror and Horror were able to produce some strange vinyl that shouldn’t play on a record, but do.

Most of VTaH and [Daniel]’s work is centered on a CNC router. This soundscape took two records to produce. The spare rectangles were cut from a second record and designed to be press-fit into the host. When the newly assembled record is played, truly bizarre ‘skipping-but-still-playing’ sounds are made. The same process was used on the puzzle piece record the guys made.

The experiments continued by cutting a circle out of a record and gluing it back into place with a different orientation. This idea was taken to its logical conclusion that serves as the exemplar of music concrete.

[Daniel] and Vinyl Terror and Horror came up with a pretty neat spin (HA!) on century-old way of making electronic music, so we’ll give all of them some props. Check out all the videos from VTaH’s time at EMS after the break.

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Lighted Acrylic Christmas Ornaments

December 14, 2011 by Mike Szczys 6 Comments

If you’ve gone to the trouble of building your own CNC mill we know you’re always on the lookout for things to use it for. [Boris Landoni] wrote in with just the thing for the holiday season; a set of lighted acrylic Christmas ornaments.

One of the interesting properties of acrylic is how it reacts when edge-lit. The material pipes the light, until it bounces off of a disturbance in the surface. The first step is to design the outline of the ornament as all cut edges will glow. Next, [Boris] uses artCAM to design the internal parts to be cut. This application translates the relief cuts necessary to really make your design shine (sorry, we couldn’t resist). The best examples of this are the angel and candle seen above.

Each of these acrylic pieces has a slot cut on the bottom to hug an LED. [Boris] used small project boxes with a PCB for that diode, as well as a button battery for power.

Laser Cutting Technique Makes Plywood Bendable

December 7, 2011 by Mike Szczys 42 Comments

Here’s a laser cutting technique that makes thin plywood bendable. By cutting away elongated diamond shapes from the material, a lattice of strips connected minimally by alternating tabs is left over. The wood is then bendable, and it must be somewhat durable since the idea came from a product that uses the technique as a hinged notebook enclosure.

We don’t have much interest in it as an often used pivot point as surely it must be a problem with long-term use. But we love the look of it as a rounded corner on an enclosure like the Arduino project box seen above. The side walls are one continuous piece, with identical top and bottom sections which receive the alignment tabs. The whole thing is held together with just four bolt/washer/nut combinations.

But if you don’t have access to a laser cutter, we guess you’ll have to stick to altering pre-made enclosures for now.

Milling Interlocking Wooden Rings

December 1, 2011 by Mike Szczys 22 Comments

[Johan von Konow] wanted to make something special as a wedding gift to his wife. He decided a pair of interlocking miniature rings would be the perfect keepsake. He started his search for a way to mill the wooden rings from a solid piece of wood, and documented his journey for our enjoyment.

This project poses an interesting challenge. Most CNC mills offer three axes of freedom, but he only had a 2D mill meant for routing PCBs. This means the cuts can only be made from the top down at one depth. In order to fabricate the rings he needed to cut from more than one side. With more study, [Johan] discovered that it would be necessary to cut the wood stock from eight different angles before the rings would be complete.

The solution to the problem was to first mill a jig to hold the wood stock. It has positions to hold the stock at each different angle. The final step before starting the cut was to mill the stock itself to perfectly fit his custom jig. We think it turned out great, thanks in part to hand filing, sanding, and polishing to smooth the marks left from milling.

OpenPnP Working To Create An Affordable And Completely Open Pick And Place Machine

November 30, 2011 by Mike Nathan 21 Comments

open-pick-and-place

If you happen to do a lot of SMD work, a pick and place machine is an incredible time saver. The problem is that most automated pick and place solutions are well outside of the “small outfit” price range, let alone the budget of a hobbyist.

We have seen some great DIY pick and place implementations around here, though most are lacking professional features or the sort of documentation that would make it easy for others to replicate. The OpenPnP project is looking change things, with a completely open source hardware and software solution with a price target of under $1,000.

Things are already well under way, with plenty of details available in the project’s wiki. According to the development page, a prototype should go into construction in the near future, and development of the pick and place’s control software is coming along nicely.

While things are looking great for the OpenPnP project, they can always use some help to keep things moving. Be sure to check out the project page if you are interested in lending a hand.

To see some of the progress being made, stick around to see a short demo video of the control software and camera in action.

[via Make]

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