Is It A Toy? A Prototype? It’s A Hack!

May 16, 2020 by Elliot Williams 2 Comments

Some of the coolest hacks do a lot with a little. I was just re-watching a video from [Homo Faciens], who after building a surprisingly capable CNC machine out of junk-bin parts and a ton of ingenuity, was accidentally challenged by Hackaday’s own [Dan Maloney] to take it a step further. [Dan] was only joking when he asked “Can anyone build a CNC machine out of cardboard and paperclips?”, but then [Homo Faciens] replied: cardboard and paperclip CNC plotter. Bam!

My favorite part of the cardboard project is not just the clever “encoder wheel” made of a bolt dipped in epoxy, with enough scraped off that it contacts a paperclip once per rotation. Nor was it the fairly sophisticated adjustable slides and ways that he built to mimic the functionality of the real deal. Nope.

My favorite part of this project is [Norbert] explaining that the machine has backlash here, and it’s got play there, due to frame flex. It is a positive feature of the machine. The same flaws that a full-metal machine would have are all present here, but due to the cheesy construction materials, you can see them with the naked eye instead of requiring a dial indicator. Because it wiggles visible tenths of an inch where a professional mill would wiggle invisible thousandths, that helps you build up intuition for the system.

This device isn’t a “prototype” because there’s no way [Norbert] intends it for serious use. But it surely isn’t just a “toy” either. “Instructional model” makes it sound like a teaching aid, created by a know-it-all master, intended to be consumed by students. If anything, there’s a real sense of exploration, improvisation, and straight-up hacking in this project. I’m sure [Norbert] learned as much from the challenge as we did from watching him tackle it. And it also captures the essence of hacking: doing something unexpected with tech.

Surprise us!

Printable, Castable Feeders Simplify Pick-and-Place Component Management

May 14, 2020 by Dan Maloney 10 Comments

It goes without saying that we love to see all the clever ways people have come up with to populate their printed circuit boards, especially the automated solutions. The idea of manually picking and placing nearly-microscopic components is reason enough to add a pick and place to the shop, but that usually leaves the problem of feeding components to the imagination of the user. And this mass-production-ready passive component feeder is a great example of that kind of imagination.

Almost every design we’ve seen for homebrew PnP component feeders have one of two things in common: they’re 3D-printed, or they’re somewhat complex. Not that those are bad things, but they do raise issues. Printing enough feeders for even a moderately large project would take forever, and the more motors and sensors a feeder has, the greater the chance of a breakdown. [dining-philosopher] solved both these problems with a simple design using only two parts, which can be resin cast. A lever arm is depressed by a plunger that’s attached to the LitePlacer tool, offset just enough so that the suction cup is lined up with the component location on the tape. A pawl in the lower arm moves forward when the tool leaves after picking up the part, engaging with the tape sprocket holes and advancing to the next component.

[dining-philosopher] didn’t attack the cover film peeling problem in his version, choosing to peel it off manually and use a weight to keep it taut and expose the next component. But in a nice example of collaboration, [Jed Smith] added an automatic film peeler to the original design. It complicates things a bit, but the peeler is powered by the advancing tape, so it’s probably worth it.

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OpenScan 3D Scans All Of The (Small) Things

April 25, 2020 by Donald Papp 22 Comments

The OpenScan project has been updated quite a bit since its inception. OpenScan is an open source, Arduino or Raspberry Pi-based 3D scanner for small objects that uses 3D printed hardware and some common electronic components to create 3D scans using photogrammetry; a process by which a series of still images from different angles are used to create a 3D point cloud of an object, which can then be used to generate a 3D model.

Feature visualization overlays detected features onto the camera preview to help judge quality. Broadly speaking, green is good.

Photogrammetry is a somewhat involved process that relies on consistent conditions, so going through the whole process only to find out the results aren’t up to snuff can be tiresome. Happily, OpenScan offers some interesting new functions such as feature visualization via the web interface, which helps a user judge scan quality and make changes to optimize results without having to blindly cross their fingers quite so much. OpenScan remains a one-person project by [Thomas], who is clearly motivated to improve his design and we’re delighted to see it getting updates.

Embedded below is a video that walks through the installation and web interface. It’s a fairly long and comprehensive, but if you like you can skip directly to [Thomas] demonstrating the interface around the 8:22 mark, or watch it below. Interested in your own unit? [Thomas] has an e-shop for parts and the GitHub repository is right here; the project also has its own subreddit.

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Plasma Cutter + Sharpie Is Surprisingly Useful

April 10, 2020 by Al Williams 14 Comments

What we want is a Star Trek-style replicator. What we have are a bunch of different machines that can spew out various 2D and 3D shapes. For the foreseeable future, you’ll still need to post-process most of what you build in some way. [Stuff Made Here] had a challenge. He often uses his plasma cutter to create complex sheet metal items. But the cutter is two dimensional so the piece doesn’t look right until you bend it at just the right places. If you are doing a simple box, it is easy to figure out, but getting just the right spot on a complex bend can be a challenge. His answer? Attach a marker to the gantry so the machine can draw the lines right on the sheet metal.

Sounds easy and if you were willing to do a pen pass separately and then remove the pen and do the plasma cutting it would be relatively easy. However, that seems kind of crude. Mounting it permanently requires a way to raise it up when cutting — and it needs to survive the noisy environment near the torch. The pen would also dry out if you left in uncapped. The answer was using a permanent marker with a click retractor and let the mechanism extend and retract the pen point on command.

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Making PCBs With A Vinyl Cutter

April 1, 2020 by Richard Baguley 26 Comments

You might assume that you need a lot of expensive stuff to make your own PCBs, but that isn’t the case: you can do it with a vinyl cutter and a few common chemicals and tools. [Emiliano Valencia] has laid out the entire process. While we’ve seen plenty of make your own PCB guides before, this one goes a bit further as it covers using the vinyl cutter to make solder masks, so you can use it for surface mount designs.

The end result of the process that [Emilano] lays out is the tinyDice, a cute little electronic die that can fit on a keyring. The whole process is very well written up, and even experienced PCB makers will probably find a few useful tricks here.

The really interesting part for us was using the vinyl cutter to make three parts of the process: the etching mask, the solder mask that protects the traces and the solder stencil that applies the solder to the pads for surface mounting. Continue reading “Making PCBs With A Vinyl Cutter” →

Turn By Wire Is A Machinist’s Sixth Sense

March 24, 2020 by Sonya Vasquez 14 Comments

It’s hard not to be a little intimidated by the squeaks and whirs that come with your first journey into a machine shop. Here, skilled machinists pilot giant hunks of cast iron that turn metals into piles of chips to yield beautiful parts. But what if machine tools themselves didn’t have to seem so scary. What if using them could feel a bit more intuitive, even, dare we say, natural from the get-go?

Enter Turn by Wire, a unique set of force feedback and machine control concepts applied to a lathe brought to you by researchers [Rundong Tian], [Vedant Saran], [Mareike Kritzler], [Florian Michahelles], and [Eric Paulos] at Berkelely.

Turn by Wire vastly reimagines the relationship between a user’s control inputs and the machine outputs in two ways: (1) by changing the mapping between the hand cranks and machine movements and (2) by changing the haptic feedback felt by the machinist. Since both of these interactions can be defined programmatically, the researchers created three unique ways of interacting with the lathe. First, by defining a tool path in the graphic user interface (GUI), the machinist can use a single hand crank to step forward and back in time along that toolpath. Second, by applying virtual guidelines in the GUI, both the machine and the hand cranks will physically snap to the guide lines when they are sufficiently close. Finally, the hand cranks can be used to teach the machinist a technique by adding resistive forces into the hand cranks depending on movement while a machinist is stepping through a process like peck drilling.

This is a great example of [Tom Knight’s] “just wrap a computer around it!” as mentioned by [Bunnie Huang] when we featured the IQ Motor Modules. It’s a powerful example of how putting a computer between the controls and the machine can correct for real world imperfections, be they in the mechanics of the machine of the operator. For the curious, have a look at [Rundong’s] paper published at UIST and [Vedant’s] master’s thesis.

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A Boring Tale With Six Sides

March 23, 2020 by Jenny List 18 Comments

Making a hole in a piece of material is a straightforward process, after all most of us will have some form of drill. If we need a hole that isn’t round though, after the inevitable joke about bad drill control leading to oval holes, what do we do? Get busy with a file perhaps? Or shell out for a shaped punch? [Skunkworks] has taken a different tack, using LinuxCNC and a vertical mill to machine near-perfect hexagonal and other polygonal holes.

The tool path appears to be more star-shaped than polygon shaped, the reason for which becomes apparent on watching the videos below the break as the rotation of the tool puts its cutting edge in a polygonal path. Anyone who has laboured with a file on a round hole in the past will be impressed with this piece of work.

The latest in the saga takes the work from simple hexes into other shapes like stars, and even tapered polygonal holes. These in particular would be a significantly difficult task by other means, so we look forward to what other developments come from this direction.

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