HHH: PCB Mill From Connecticut Hackerspace

October 23, 2013 by Mike Szczys 15 Comments

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The latest Hackaday Hackerspace Henchmen entry comes from [Bremster] and the Connecticut Hackerspace. He mentions that he’s been meaning to write about the PCB/engraving mill used at the hackerspace for some time, but it was the HHH program which motivated him to do so. Yay! That’s exactly what we envisioned with this and we hope there are more submissions which will encourage us to continue and expand the program.

We think this is a perfect CNC project for any hackerspace whose members are into electronics. It’s compact, and we find milling PCBs to be more desirable than chemically etching them; the tool should get quite a bit of use. This particular build uses x, y, and z axis hardware which was pulled separately from unknown machinery. Like any good hacking project, the fabrication process was so addictive that [Bremster] stayed at the space all night, breaking at 5am to shower and eat before heading to work.

It originally used a Dremel rotary tool but had too much play in the mounting mechanism. When they replaced it with the motor shown above they also machined an aluminum bracket that dramatically stabilizes the cutting bit. This results in clean PCBs, and they’ve even used it to make stamps for their hackerspace passports. There is an enclosure attached, which has been hinged to the right for the two images above.

Check out the demo video below, and get your own CNC submission in for the HHH program before the October 31st deadline.

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Introducing The Shapeoko 2

October 21, 2013 by Brian Benchoff 39 Comments

For all the 3D printers that hit the Hackaday tip line, it’s surprising we don’t see more CNC routers. They’re arguably more useful tools, and with the ability to mill wood, plastic, and non-ferrous metals, open up the door to a whole bunch more potential builds. One of the most popular – and certainly one of the least expensive – CNC routers out there, the Shapeoko, just received a huge update that makes this minimal machine even more capable.

The new Shapeoko 2 keeps the same V wheel on an aluminium extrusion design with Makerslide, but fixes a few problems that limited the original Shapeoko. There’s a larger work area on this version, and the Y axes feature dual stepper motors. The biggest feature, we think, is the ability to handle materials larger than the machine itself thanks to its open front and back.

The Shapeoko 2 is available in two versions, a $300 mechanical kit that requires you to go out and get some motors, a power supply, and a grblShield, the full version, for $650, includes everything you’ll need to start routing wood metal and plastic at home.

HHH: CNC Storage Base From The Rabbit Hole

October 18, 2013 by Mike Szczys 18 Comments

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Remember when we announced the Hackaday Hackerspace Henchmen program and asked you to send in the best CNC hacks from your Hackerspace? Well so far this is the only entry, which puts [Mazz] in the top spot to take all the loot for himself. Send in your projects by 10/31/13 if you want a shot at stickers, shirts, and a parts vendor gift card.

What he sent in is a storage cabinet base built for his hackerspace — The Rabbit Hole in Rochester, Minnesota. The group managed to get their hands on a CarveWright CNC machine but didn’t have a spare bench to put it on. The thought of dropping a lot of cash into something wasn’t appealing to them. But as luck would have it, about the same time this arrived at the space one of the members spied a free filing cabinet curbside.

The cabinet was a vertical four-drawer unit. It was chopped in half, with the resulting two-drawer units bolted side-by-side to each other. From here a frame was built to support the cabinets, along with locking casters so that it’s easy to move around. The inaugural run with the new machine/cabinet combination was to mill a sign for the space:

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Unorthodox Home-made CNC Machine

October 17, 2013 by James Hobson 61 Comments

Here’s a rather unorthodox home-made CNC machine we haven’t seen before!

[ModHappy] recently accepted a challenge to design and build a CNC machine out of cheap and readily available components from a hardware store.

Wandering around the store he noticed the plumbing isle and he started playing around with PVC pipes on the floor, greatly confusing the store employees. He had a frame constructed, but still needed a way to achieve linear movement. His calls were answered in the electrical isle, where he made use of conduit wall-mounts! They only required a minor modification to go from gripping the pipe, to sliding along it. A few fasteners later, some stepper motors from a broken scanner, a CD-ROM drive for the z-axis, some hacked together couplers using set screws, and the mechanical build was complete.

On the controls end, he made use of a cheap Chinese TB6560 CNC driver board off eBay, which he modified slightly to increase reliability. The whole thing runs off LinuxCNC (which is free) on his old laptop — good to note, it can also be run live if you aren’t yet enlightened with a Linux OS.

Stick around after the break to see it in action, drawing out an awesome site’s logo!

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PACCAM: Interactive 2D Part Packing

October 14, 2013 by James Hobson 12 Comments

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Do you have a laser cutter or CNC router? How much material do you waste from project to project due to inefficient part packing? Enter PACCAM, a software interface designed by [Daniel Saakes] to aid in efficient 2D part packing.

Using a cheap webcam, it is possible to capture the outline of used material, exactly where it is located in the CNC machine. The software then can limit your workspace to the material available in the machine. New parts can then be dragged into place, automatically avoiding interferences — certain algorithms also exist to utilize the remaining material most efficiently.

Looking to engrave custom items? The software can do that too by showing you the material (or in this case, object), you can simply drag your design onto the material available, without having to worry about aligning your object inside the CNC machine!

In the video after the break, [Daniel] shows just how powerful and useful the software is by putting a crooked, cookie-cutter riddled piece of material in the machine, and then using the software to cut new parts out of what would be scrap material in any other shop.

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CNC Software Toolchain Using Only Open Source Software

October 12, 2013 by Mathieu Stephan 53 Comments

For hobbyists, there are two types of machines that can make parts at home. The first type is matter-adding machines (3D printers) and the other is matter-subtracting machines (like CNC milling machines). [Mario] recently tipped us about an article he made detailing which free software can be used to design and produce parts on CNC machines.

The first step of the process is obviously designing the part you want to make using a Computer-Aided Design (CAD) application. [Mario] suggests Heeks or Freecad for which you can find plenty of tutorials on YouTube. The next step consists in converting the part you just designed to machine tool paths using a Computer-Aided Manufacturing (CAM) application. Fortunately, Heeks can do both so it may be the best option for beginners. [Mario] also mentions the pcb2gcode application, which allows you to manufacture printed circuit boards at home for the prototypes you may want to produce. Finally, the well known LinuxCNC (previously Linux EMC2) software is used to control the CNC machine using the GCode that the CAM software produced.

At Hackaday, we’d really like knowing what our readers currently use for their CNCs so don’t hesitate to leave us a comment below.

Home Made CNC Reuses Printer Parts

October 4, 2013 by Adam Fabio 13 Comments

Do it yourself CNC machines can be never ending projects. Once you get one machine done, you want another. [Mario] found this out when he started work on his second CNC machine, TheMaker2. As its name implies, TheMaker2 is the successor to TheMaker1. It seems that [Mario] was trying to walk the fine line of precision at minimal cost. He wanted a rigid frame, so he chose to go with a moving table, rather than the moving gantry of TheMaker1. The frame is made up of galvanized steel stock, which makes it much stronger than many DIY CNCs out there. [Mario] had a friend weld the steel up for him, we hope he took the proper precautions when welding galvanized material.

Standard threaded rod was used as lead screws, with some very well made anti backlash nuts. Acme thread would have been a better choice here, however [Mario] doesn’t say if acme stock was available to him. Most of the mounts and small parts are made from easily worked PVC sheet stock. Precision rails were scavenged from old Ricoh copiers. Epson printers provided the tubing which became motor couplers.

One negative in this build are the stepper motors. [Mario] used NMB PM55L-048 motors he had pulled from HP printers. These motors have both a wide step angle (7.5 degrees) and a rather anemic torque. Thankfully [Mario] mentions upgrading NEMA 23 motors in the comments of TheMaker2’s instructables page.