How To Build With Acrylic Using The Tools You Have

July 26, 2021 by Tom Nardi 8 Comments

In a perfect world, we’d all have laser cutters and could pop intricate designs out of acrylic sheets with just a few clicks of the mouse. But in reality, most of us have to make do with the pedestrian tools we have at hand. For many, that might even mean everything has to be done by hand. Luckily, [Eric Strebel] has been working on a series of videos that cover how you can make professional looking parts out of acrylic using a wide array of common tools.

Solvent welding hand-cut pieces of acrylic.

The first video demonstrates how a simple cube can be constructed by a band saw, a table saw, and if need be, with hand tools. You might think the two power saws would have similar results, but as [Eric] explains, the table saw ends up being far more accurate and requires less post-processing to get a smooth edge. Ideally you’d run the cut pieces through a router to bevel them, but that’s a tall order for many home gamers.

As for the hand tool approach, scoring and snapping the sheets ends up making a surprisingly clean break that can actually be cleaner than the edge you’d get with a power tool. No matter how you cut them, [Eric] shows the proper way to apply the water-like solvent to your acrylic pieces to create a strong and visually attractive bond.

The next video in the series covers more advanced techniques that can still be pulled off without a top-of-the-line workshop. Sure the water-cooled acrylic bender he has is pretty slick, but if you can’t afford the $100 USD gadget, he shows you how to get similar results with an old toaster oven that you can pick up from the thrift store or even the side of the road. With some hand-made jigs and molds, you can warp and flex the heated plastic into whatever shape your project needs. Combining the tips from both videos, you might be surprised at what can be created with little more than a ruler, some hot air, and the appropriate techniques.

These are just the latest in a long line of fantastic videos that [Eric Strebel] has produced about at-home design and fabrication. Whether its making a two part silicone mold or creating functional prototypes out of foam board, there’s an excellent chance that he’s covered a topic you’ve wanted to learn more about.

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New Video Series: Designing With Complex Geometry

July 22, 2021 by Tom Nardi 17 Comments

Whether it’s a 3D printed robot chassis or a stained glass window, looking at a completed object and trying to understand how it was designed and put together can be intimidating. But upon closer examination, you can often identify the repeating shapes and substructures that were combined to create the final piece. Soon you might find that the design that seemed incredibly intricate when taken as a whole is actually an amalgamation of simple geometric elements.

This skill, the ability to see an object for its principle components, is just as important for designing new objects as it is for understanding existing ones. As James McBennett explains in his HackadayU course Designing with Complex Geometry, if you want to master computer-aided design (CAD) and start creating your own intricate designs, you’d do well to start with a toolbox of relatively straightforward geometric primitives that you can quickly modify and reuse. With time, your bag of tricks will be overflowing with parametric structures that can be reshaped on the fly to fit into whatever you’re currently working on.

His tool of choice is Grasshopper, a visual programming language that’s part of Rhino. Designs are created using an interface reminiscent of Node-RED or even GNU Radio, with each interconnected block representing a primitive shape or function that can be configured through static variables, interactive sliders, conditional operations, and even mathematical expressions. By linking these modules together complex structures can be generated and manipulated programmatically, greatly reducing the time and effort required compared to a manual approach.

As with many powerful tools, there’s certainly a learning curve for Grasshopper. But over the course of this five part series, James does a great job of breaking things down into easily digestible pieces that build onto each other. By the final class you’ll be dealing with physics and pushing your designs into the third dimension, producing elaborate designs with almost biological qualities.

Of course, Rhino isn’t for everyone. The $995 program is closed source and officially only runs on Windows and Mac OS. But the modular design concepts that James introduces, as well as the technique of looking at large complex objects as a collection of substructures, can be applied to other parametric CAD packages such as FreeCAD and OpenSCAD.

Designing with Complex Geometry is just one of the incredible courses offered through HackadayU, our pay-as-you-wish grad school for hardware hackers. From drones to quantum computing, the current list of courses has something for everyone.

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New Video Series: Learning Antenna Basics With Karen Rucker

July 15, 2021 by Dan Maloney 21 Comments

We don’t normally embrace the supernatural here at Hackaday, but when the topic turns to the radio frequency world, Arthur C. Clarke’s maxim about sufficiently advanced technology being akin to magic pretty much works for us. In the RF realm, the rules of electricity, at least the basic ones, don’t seem to apply, or if they do apply, it’s often with a, “Yeah, but…” caveat that’s sometimes hard to get one’s head around.

Perhaps nowhere does the RF world seem more magical than in antenna design. Sure, an antenna can be as simple as a straight piece or two of wire, but even in their simplest embodiments, antennas belie a complexity that can really be daunting to newbie and vet alike. That’s why we were happy to recently host Karen Rucker’s Introduction to Antenna Basics course as part of Hackaday U.

The class was held over a five-week period starting back in May, and we’ve just posted the edited videos for everyone to enjoy. The class is lead by Karen Rucker, an RF engineer specializing in antenna designs for spacecraft who clearly knows her business. I’ve watched the first video of the series and so far and really enjoy Karen’s style and the material she has chosen to highlight; just the bit about antenna polarization and why circular polarization makes sense for space communications was really useful. I’m keen to dig into the rest of the series playlist soon.

The 2021 session of Hackaday U may be wrapped up now, but fear not — there’s plenty of material available to look over and learn from. Head over to the course list on Hackaday.io, pick something that strikes your fancy, and let the learning begin!

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Design A Custom Enclosure Using Modelling Clay And Photogrammetry

July 14, 2021 by Maya Posch 12 Comments

When it comes to designing enclosures which aren’t simple boxes or other basic shapes, the design process tends to get somewhat tedious and involved as the number of measurements to be transferred into the CAD program begins to skyrocket. One possible shortcut here is detailed by [Sebastian Sokolowski], who describes a process that combines modelling clay with photogrammetry.

[Sebastian] covers the design of a hand-held controller that should fit ergonomically when grasped. This starts off with the electronics and mechanical components that have to fit inside the controller: inside a CAD tool (demonstrated in Fusion 360), these components are arranged with a simple box enclosure around them. This box is then 3D printed and with modelling clay the desired shape of the controller is created around this box.

With a modelling clay version of the controller ready, it is photographed from as many angles as possible before these photos are processed by the open source Meshroom tool into a 3D model. After fixing up some issues in the mesh and knocking down the vertex count on this model so that the CAD tool doesn’t suffer a seizure importing it, it’s ready for final processing.

Within the CAD tool all that is left now is to refine the imported model to refine its outer shape and to create the inner details for mounting the electronics, switches and other components.

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Flexible Prototyping For E-Textiles That Doesn’t Cost An Arm And A Leg

June 22, 2021 by Kristina Panos 3 Comments

Let’s face it: pretty much everything about e-textiles is fiddly. If wearables were easy, more people would probably work in that space. But whereas most circuit prototyping is done in two dimensions, the prototyping of wearables requires thinking and planning in 3D. On top of that, you have to figure out how much conductive thread you need, and that stuff’s not cheap.

[alch_emist] has a method for arranging circuits in 3D space that addresses the harsh realities of trying to prototype wearables. There’s that whole gravity thing to deal with, and then of course there are no straight lines anywhere on the human body. So here’s how it works: [alch_emist] made a bunch of reusable tie points designed to work with an adhesive substrate such as felt. They laser-cut a set of acrylic squares and drilled a hole in each one to accommodate a neodymium magnet. On the back of each square is a small piece of the hook side of hook-and-loop tape, which makes the tie points stay put on the felt, but rearrange easily.

We love the idea of prototyping with felt because it’s such a cheap and versatile fabric, and because you can easily wrap it around your arm or leg and see how the circuit will move when you do.

Not quite to this planning stage of your next wearable project? Magnets and conductive thread play just as well together in 2D.

A Model Of Dry Humor

June 18, 2021 by Brian McEvoy 5 Comments

If you want to see a glorious combination of model bananas in a treehouse mixed with a lot of tongue-in-cheek humor, you will appreciate [Studson]’s build video. Video also after the break. He is making an homage to Donkey Kong 64 from 1999, which may be a long time ago for some folks’ memory (Expansion Pak). Grab a piece of your favorite banana-flavored fruit and sit tight for joke delivery as dry as his batch of baked bark.

The treehouse uses a mixture of found material and crafting supplies. In a colorful twist, all the brown bark-wielding sticks are green, while the decorative greenery came from a modeling store shelf. It all starts with a forked branch pruned from the backyard and a smooth-sided container lid that might make you look twice the next time you nuts are buying a bin of assorted kernels. If you thought coffee stirrers couldn’t be used outside their intended purpose, prepare to have your eyes opened, but remember to wear eye protection as some of the wood clippings look like they could achieve escape velocity. The key to making this look like an ape abode, and not a birdhouse, is the color choices and finishing techniques. Judging by the outcome and compared to the steps, making a model of this caliber is the sign of an expert.

If you wish to binge on wooden Donkey Kong, we can grant your desire, but if you prefer your treehouses life-sized, this may launch your imagination.

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Waterslide Decals For Wingding Keycaps

June 12, 2021 by Kristina Panos 24 Comments

We know this feeling all too well [YOHON!] spent $340 building, lubing, and filming a custom keyboard and it still wasn’t perfect until they got the keycaps sorted. They bought blank ‘caps because they’re awesome, but also because they wanted to make their own custom ‘caps for all those painstakingly lubed and filmed Gateron yellows. At first [YOHON!] thought about doing it DIY dye-sublimation style with a hair straightener and polyimide tape, but that is too permanent of a method. Instead, [YOHON!] wanted room to experiment, make changes, and make mistakes.

Eventually, [YOHON!] learned about waterslide decals and settled on doing them that way. Every step sounds arduous, but we think it was way worth it because these look great. Since [YOHON!] wanted the keyboard to be weird, they designed a cute little symbol for each key which gives it a cryptic-but-accessible Wingdings feel.

We think these pictograms are all totally adorable, and we particularly like the owl for O, the volcano for V, and of course, the skeleton for X is a solid choice. Oh, and there’s a tiny fidget spinner knob to round out the cuteness. Designing and applying the keycaps took longer than the entire keyboard build, but you can check out the sped-up version after the break.

Want to just throw money at the keycaps problem? You may not want an entire keyboard full of cheeseburger and hot dog keycaps, but one or two fun keycaps are pretty cool to have. If you want to make your custom keycaps more permanent and don’t like the dye sublimation trick, try 3D printing them.

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