Wireless Controller Operates Your CNC Mill

May 28, 2011 by Mike Szczys 7 Comments

[Darrell Taylor] wanted to add a CNC control pendant to his mill but didn’t want to foot the bill which can often run several hundred dollars. These pendants are basically a physical remote control that operates the CNC software that controls the machine. Since he was already using a Linux box running EMC2, it wasn’t too hard to figure out how to operate the mill with a PlayStation controller.

To get the controller talking to his Linux machine he uses a package called QtsixA. The package identifies and loads the control through Bluetooth pairing. From there it can be used to map the buttons and joysticks as keys on the keyboard or as a mouse. In the video after the break [Darrell] demonstrates how he has his shortcuts set up. He’s able to move the machine head, and even start or step through the programmed routine. As he mentions, this is pretty nice if you’ve got dirty hands; just throw the controller in a zipper bag and you’re set to go.

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Why Build A CNC Mill When You Can Have A Chess Robot Instead?

May 23, 2011 by Mike Szczys 9 Comments

[Patrick McCabe] enjoys the challenge of playing chess against the computer but he wasn’t satisfied with the flat experience of on-screen gaming. No problem, he just built his own gantry-style chess robot that he can play against. Don’t be confused, he still doesn’t have to touch the pieces, but instead uses the dedicated control board seen on the left of the image above. The robotic arm that is mounted on a gantry takes care of moves for both players.

It’s a pretty normal CNC build, using four stepper motors to slide the moving bits along precision rod. An Arduino Mega drives the system, with a PC doing the heavy lifting using a program called My Robot Lab.

We certainly like it that [Patrick] spent a little bit of time making the cabinet and visible parts look nice. Chess is a civilized game and unfinished parts would be out-of-place. We didn’t see it in his writeup, but the one feature we’re really hoping he has implemented is the ability to have the robot automatically reset the board at the beginning of a game.

As you might have guess, you’ll find embedded video after the break.

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BAMF2011: Lasersaur Is One BIG Laser Cutter!

May 22, 2011 by Phil Burgess 38 Comments

Psst…wanna buy a laser cutter, but not ready to sell your internal organs? Nortd Labs’ Lasersaur project aims to create an open source large-format laser cutter/engraver that undercuts (har har!) the cost of commercial models by an order of magnitude.

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Making A 3D Printer Work Wirelessly

May 21, 2011 by Mike Szczys 10 Comments

Looking for more ways to enhance his 3D printer, [JJ] decided to make it wireless. He got his hands on some $10 Bluetooth modules and figured this would be just the thing to make the link with his laptop.

They came as surface mount modules, so the first thing he had to do was develop a breakout board that he could patch into his Ultimaker 3D printer. This provided a nice opportunity as he needed to do some level converting to make the 3.3V module play nicely with his 5V CNC electronics. The first version of the board turned out well but he had really a poor communications range. The second version, which is pictured above, hangs the module’s antenna off the edge of the breakout board and works a lot better.

We’ve embedded a clip after the break that walks through the development of this board. [JJ] shared the Eagle CAD files as a megaupload link, but we’ve also mirrored the file after the break for your convenience.

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Adding A Tachometer To The SX2 Mini Mill

May 12, 2011 by Mike Nathan 13 Comments

sx2_mill_tach

[Jeff] recently bought an SX2 mini milling machine with plans to eventually automate it for use as a CNC mill. After paying nearly $700 for the mill, he decided there was no way he was willing to pay for the $125 tachometer add on as well. Instead, he reverse-engineered the mill and constructed a tachometer of his own.

He opened the control box and started looking around. After identifying most of the components, he got sidetracked by a 3-pin header that didn’t seem to have any particular function. That is, until he realized that a lathe by the same manufacturer uses the same components, and figured that the header might be used for reversing the motor. Sure enough he was right, and after adding a reverse switch, he got back to business.

He probed the 7-pin socket with his logic analyzer and quickly picked out the mill’s data line. He hooked the line up to an Arduino and in no time had the RPM displayed on an LCD screen.

[Jeff] says that this little experiment is the first of many, since the mill is so hacker friendly. We definitely look forward to seeing a CNC conversion tutorial in the near future.

A Weighted Companion Cube Worth Saving From The Incinerator

May 4, 2011 by Mike Nathan 19 Comments

companion_cube

It’s honestly sad that Valve has not released any official Portal-related items to the masses, as a market for them clearly exists. As the saying goes, “necessity is the mother of invention”, and [Jamie] needed a Weighted Companion Cube in the worst way.

Actually he constructed his Companion Cube in order to test out some modifications and upgrades he performed on his homebrew CNC Mill. Judging by how the cube turned out, and the fact that he was able to keep tolerances within .005”, we would say that his mill is working just fine.

The cube was designed in Solidworks, and passed through the BobCAD plugin to generate the GCode for the mill. The base of the cube was machined out of a 3” solid block of aluminum, hollowed out on one side to give him access to the cube’s innards. He milled out heart shaped openings on each side, covering them with frosted Lexan.

He added a BlinkM to the mix, mounting it on the cover plate he milled for the open side of the cube. Once lit it cycles through several colors, including the pinkish tone anyone who has played Portal is quite familiar with.

We would say that it’s a great job, but it doesn’t do his work justice – it’s absolutely stunning. We’re not just saying that because we want one, though we do want one…badly.

PCB Milling Tutorial

April 22, 2011 by Mike Szczys 26 Comments

[Juan Jose Chong] put together a set of videos and a PDF guide to milling printed circuit boards. You’ll find the pair of videos, totaling about twenty-two minutes, embedded after the break. In them, [Jaun] details the techniques used by the IEEE chapter at Texas Tech University to mill PCBs instead of using the traditional method of etching them. We’ve long been a fan of milled PCBs and often dream about the day we can retire the old iron we use for the toner transfer method.

In the tutorial, IsoPro is the software used to control the mill. The CAM files from a PCB design program are imported – they can come from many different programs including EagleCAD. A few setup steps let the operator configure the resolution necessary to mill the correct tolerance and from there the paths that outline each trace are calculated in software. In order to facilitate double-sided boards a reference hole is drilled in the copper clad board to accept a post on the mill table. Tape down the substrate with some foil tape, set the depth of the end mill bit, and let the machine do its thing. [Juan’s] video illustrates how quickly this can produce a rather complicated board, finishing in around 20 minutes.

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