Milling A Motorcycle Engine

June 20, 2012 by Mike Szczys 30 Comments

Real motorcycle enthusiasts design and mill their own engines. Well, perhaps that’s an overstatement. Certainly it takes to more obsession than enthusiasm to go to these lengths. But this gentleman’s modifications started out simple enough, and managed to make it to the most extreme of hardware fabrications.

The used bike came with a modified camshaft that seemed like a botched job. As he got further into tuning up engine performance the prospect of just replacing the entire thing with his own design started to grow. Using a manually operated milling machine he cut his own molds for the new cylinder head out of wood and sent them off to be forged out of aluminum. They come back in rough shape but he just “filed the cast without mercy” and machined the tolerances to his specifications. Apparently the first test ride had him a bit nervous — he also milled his own brakes for the bike. But after a few times around the block he gained confidence with his work.

[Thanks Carlos]

Salvaged Robot Arm Makes A Big 3d Printer

June 19, 2012 by Mike Szczys 34 Comments

Wow, building a precision 3d printer is amazingly easy if you can get your hands on an industrial-quality robot arm. [Dane] wrote in to tell us about this huge extruder printer made from an ’80s-era SCARA robot arm. It is capable of printing objects as large as 25″x12″x6.5″.

This 190 pound beast was acquired during a lab clean out. It was mechanically intact, but missing all of the control hardware. Building controllers was a bit of a challenge since the it’s designed with servo motors and precision feedback sensors. This is different from modern 3d printers which use stepper motors and no feedback sensors. A working controller was built up one component at a time, with a heated bed added to the mix to help prevent warping with large builds. We love the Frankenstein look of the controller hardware, which was mounted hodge-podge as each new module was brought online.

You can see some printing action in the clip after the break. A Linux box takes a design and spits out control instructions to the hardware.

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Fast And Easy Solder Paste Stencils

June 18, 2012 by Brian Benchoff 12 Comments

If you’re making your own boards with SMD parts, you might want to get a solder paste stencil. Usually made of laser-cut mylar or extremely thin steel, these stencils allow you to squeegee solder paste onto your board’s pads and make assembly a whole lot easier. [Rochey] needed a stencil for a board he was working on, and lacking a laser cutter he turned to what he had available – a few bits of plastic and a CNC machine.

[Rochey] began making his stencils out of laminating pouches and an xacto knife. This worked well, but it was time-consuming, and a bit fiddly when cutting 1 mm square holes. To speed up the process, [Rochey] put one of these laminating pouches on his CNC machine, exported the ‘Top Cream’ layer in Eagle to the CNC software of his choice, and had his machine attack the plastic with a 1 mm drill bit.

To [Rochey]’s surprise, everything went as planned; in five minutes, he had a stencil with perfectly accurate holes that masked off everything but the SMD pads.

Thanks [Fabien] for sending this one in.

Finally, A 3D Printer For Burritos

June 16, 2012 by Brian Benchoff 24 Comments

[Marko] created a robot that prints burritos. Truly, we’ve reached new heights as a species.

The Burritob0t is based on the ORD Hadron 3d printer with a pair of air compressor/syringe-based extruders based on the Makerbot Frostruder. All the ingredients – rice, meat, salsa, and molten cheese – will be printed onto the surface of a tortilla heated by a Makerbot heated build platform.

[Marko] has some pretty neat plans for his Burritob0t such as an iPhone app for ordering your burritos and some sort of social commentary thing using burritos. We’re assuming [Marko] hasn’t yet got this Burritob0t up and running for the lack of any action shots or demo videos. That said, there’s a wonderful Flickr gallery and an about page that covers the artistic statement behind the Burritob0t.

If you want to get your own Burritobot, [Marko] hopes to have a Kickstarter up sometime in July.

Mantis9 PCB Mill

June 13, 2012 by Mike Szczys 30 Comments

This is the Mantis9 PCB mill. It’s the first time we’ve featured the project, but it’s already well known by some as it keeps popping up in the comments for other CNC mill projects. Yes, it’s made out of wood — which some frown upon — but we’re happy with the build instructions and the especially the price tag (parts as low as $85).

We did feature an earlier revision of the hardware back in 2010. Subsequent versions changed the frame to use an open-front design, but it’s the build techniques that saw the biggest evolution. The problem was getting the holes for the parallel rods to align accurately. In the end it’s a simple operation that solves the problem; clamp both boards together and drill the holes at the same time. A drill press is used for all of the fabrication, ensuring that the holes are perpendicular to the surface of the boards. From there the rods are given some bronze bushings and pressed into place. Only then are the platforms secured to the bushings using epoxy. This is to ensure that the bushings don’t bind from poor alignment. We think it should end up having less play in it than other builds that use drawer slides.

Check out a PCB milling run in the clip after the break.

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Open Rail, Or, Why Didn’t We Think Of This?

June 12, 2012 by Brian Benchoff 54 Comments

Hackaday readers familiar with the with the CNC and automated machinery scene will be familiar with MakerSlide, the open-source linear bearing system. This linear movement system composed of special aluminum extrusions and mounting plates riding on v-wheels has been used in a lot of awesome builds including the Quantum ORD Bot 3D printer and the Shapeoko CNC router. If there’s one downside to the MakerSlide, it’s the hard-to-source aluminum extrusion with the requisite v-wheel guides. [Mark] and [Trish] of Phlatboyz have an ingenious solution to this problem: just have bolt-on v-wheel guides. It’s an idea so simple we’re kicking ourselves for not thinking of it first.

Open Rail is completely compatible with the MakerSlide linear bearing system. Instead of requiring a special aluminum extrusion, the Open rail system uses regular, plain-jane aluminum extrusions available at any reputable hardware store. Just pop a few t-nut into the Open Rail and attach it to your extrusion. Couldn’t be easier.

Considering how easy it is to find surplus aluminum extrusion, we’ll expect a few gigantic MakerSlide and Open Rail derived CNC projects in the very near future.

Calculating With 3D Printed Gears

June 11, 2012 by Brian Benchoff 5 Comments

Here’s a 3D printed electromechanical computer built by [Chris Fenton] over at NYCResistor. It uses plastic registers printed on a Makerbot, a bunch of pogo pins, and business-card sized punch cards capable of storing 32 bits of instructions and data.

In case you’re wondering, this isn’t the first time we’ve seen [Chris]’ FIBIAC. Since the last update, [Chris] managed to get a program that walks through the first three digits of the Fibonacci sequence. There’s really no limit to what the FIBIAC can theoretically do, but with only three registers he’s limited to calculating the first three digits of pi.

With more registers, [Chris]’ computer could be expanded, but each register takes about 8 hours to print. We’re sure [Chris] would gladly accept any donations of additional 3D-printed registers, so if you’d like to make a few of these gear registers you can get the files on Thingiverse.

As a proof of concept, [Chris]’ FIBIAC is amazing, but it doesn’t live up to its intended design. The punch card format [Chris] created is capable of storing 8 registers, and the registers themselves can be expanded far beyond their current 3-digit width. Still, it’s an incredible build and has the bonus of being easily expandable thanks to a very clever design.

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