3D Printing And Metal Casting Are A Great Match

December 15, 2025 by Donald Papp 21 Comments

[Chris Borge] has made (and revised) many of his own tools using a combination of 3D printing and common hardware, and recently decided to try metal casting. Having created his own tapping arm, he tries his hand at aluminum casting to create a much more compact version out of metal. His video (embedded below) really shows off the whole process, and [Chris] freely shares his learning experiences in casting his first metal tool.

The result looks great and is considerably smaller in stature than the 3D-printed version. However, the workflow of casting metal parts is very different. The parts are much stronger, but there is a lot of preparation and post-processing involved.

Metal casting deals with molten metal, but the process is otherwise very accessible, and many resources are available to help anyone with a healthy interest.

The key to making good castings is mold preparation. [Chris] uses green sand (a mixture of fine sand and bentonite clay – one source of the latter is ground-up kitty litter) packed tightly around 3D printed parts inside a frame. The packed sand holds its shape while still allowing the original forms to be removed and channels to be cut, creating a two-part mold.

His first-time castings have a rough surface texture, but are perfectly serviceable. After some CNC operations to smooth some faces and drill some holes, the surface imperfections are nothing filing, filler, and paint can’t handle.

To cast molten metal, there really isn’t any way around needing a forge. Or is there? We have seen some enterprising hackers repurpose microwave ovens for this purpose. One can also use a low-temperature alloy like Rose’s Metal, or eschew molten liquid altogether and do cold casting, which uses a mixture of resin and metal powder instead.

The design files for [Chris]’s tapping arm are available from links in the video description, and he also helpfully provides links to videos and resources he found useful. Watch it in the video, embedded just below.

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Cheap 10x10cm Hotplate Punches Above Its Weight

December 10, 2025 by Arya Voronova 14 Comments

For less than $30 USD, you can get a 10×10 centimeter hotplate with 350 Watts of power. Sounds mighty fine to us, so surely there must be a catch? Maybe not, as [Stefan Nikolaj]’s review of this AliExpress hotplate details, it seems to be just fine enough.

At this price, you’d expect some shoddy electronics inside, or maybe outright fiery design decisions, in the vein of other reviews for similar cheap heat-producing tech that we’ve seen over the years. Nope – the control circuitry seems to be more than well-built for our standards, with isolation and separation where it matters, the input being fused away, and the chassis firmly earthed. [Stefan] highlights just two possible problem areas: a wire nut that could potentially be dodgy, and lack of a thermal fuse. Both can be remedied easily enough after you get one of these, and for the price, it’s a no-brainer. Apart from the review, there’s also general usage recommendations from [Stefan] in the end of the blog post.

While we’re happy to see folks designing their own PCB hotplates or modifying old waffle irons, the availability of cheap turn-key options like this means there’s less of a reason to go the DIY route. Now, if you’re in the market for even more build volume, you can get one of the classic reflow ovens, and maybe do a controller upgrade while you’re at it.

Sudo Clean Up My Workbench

December 6, 2025 by Al Williams 20 Comments

[Engineezy] might have been watching a 3D printer move when inspiration struck: Why not build a robot arm to clean up his workbench? Why not, indeed? Well, all you need is a 17-foot-long X-axis and a gripper mechanism that can pick up any strange thing that happens to be on the bench.

Like any good project, he did it step by step. Mounting a 17-foot linear rail on an accurately machined backplate required professional CNC assistance. He was shooting for a 1mm accuracy, but decided to settle for 10mm.

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Preventing A Mess With The Weller WDC Solder Containment Pocket

December 4, 2025 by Maya Posch 30 Comments

Have you ever tipped all the stray bits of solder out of your tip cleaner by mistake? [MisterHW] is here with a bit of paraffin wax to save the day.

Hand soldering can be a messy business, especially when you wipe the soldering iron tip on those common brass wool bundles that have largely come to replace moist sponges. The Weller Dry Cleaner (WDC) is one of such holders for brass wool, but the large tray in front of the opening with the brass wool has confused many as to its exact purposes. In short, it’s there so that you can slap the iron against the side to flick contaminants and excess solder off the tip.

Along with catching some of the bits of mostly solder that fly off during cleaning in the brass wool section, quite a lot of debris can be collected this way. Yet as many can attest to, it’s quite easy to flip over brass wool holders and have these bits go flying everywhere.

That’s where [MisterHW]’s pit of particulate holding comes into play, using folded sheet metal and some wax (e.g. paraffin) to create a trap that serves to catch any debris that enters it and smother it in the wax. To reset the trap, simply heat it up with e.g. the iron and you’ll regain a nice fresh surface to capture the next batch of crud.

As the wax is cold when in use, even if you were to tip the holder over, it should not go careening all over your ESD-safe work surface and any parts on it, and the wax can be filtered if needed to remove the particulates. When using leaded solder alloys, this setup also helps to prevent lead-contamination of the area and generally eases clean-up as bumping or tipping a soldering iron stand no longer means weeks, months or years of accumulations scooting off everywhere.

Retrotechtacular: Learning The Slide Rule The New Old Fashioned Way

December 2, 2025 by Al Williams 14 Comments

Learning something on YouTube seems kind of modern. But if you are watching a 1957 instructional film about slide rules, it also seems old-fashioned. But Encyclopædia Britannica has a complete 30-minute training film, which, what it lacks in glitz, it makes up for in mathematical rigor.

We appreciated that it started out talking about numbers and significant figures instead of jumping right into the slide rule. One thing about the slide rule is that you have to sort of understand roughly what the answer is. So, on a rule, 2×3, 20×30, 20×3, and 0.2×300 are all the same operation.

You don’t actually get to the slide rule part for about seven minutes, but it is a good idea to watch the introductory part. The lecturer, [Dr. Havery E. White] shows a fifty-cent plastic rule and some larger ones, including a classroom demonstration model. We were a bit surprised that the prestigious Britannica wouldn’t have a bit better production values, but it is clear. Perhaps we are just spoiled by modern productions.

We love our slide rules. Maybe we are ready for the collapse of civilization and the need for advanced math with no computers. If you prefer reading something more modern, try this post. Our favorites, though, are the cylindrical ones that work the same, but have more digits.

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Portable Plasma Cutter Removes Rust, Packs A (Reasonable) Punch

November 29, 2025 by Donald Papp 11 Comments

[Metal Massacre Fab Shop] has a review of a portable plasma cutter that ends up being a very good demonstration of exactly what these tools are capable of. If you’re unfamiliar with this kind of work, you might find the short video (about ten minutes, embedded below) to be just the right level of educational.

Plasma cutters work by forcing compressed air through a small nozzle, and ionizing it with a high voltage. This process converts the gas into a very maneuverable stream of electrically-conductive, high-temperature plasma which can do useful work, like cutting through metal. The particular unit demonstrated also has a rust removal function. By operating at a much lower level, the same plasma stream can be used to give an effect not unlike sandblasting.

Of course, an economical way to cut metal is to just wield a grinder. But grinders are slow and not very maneuverable. That’s where a plasma cutter shines, as [Metal Massacre Fab Shop] demonstrates by cutting troublesome locations and shapes. He seems a lot more satisfied with this unit than he was with the cheapest possible (and misspelled!) plasma cutter he tried last year.

And should you want a plasma cutter, and aren’t afraid to salvage components? Consider building your own.

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Build Your Own Compact Temp Gun

November 28, 2025 by Lewin Day 4 Comments

Sometimes you need to know what temperature something is, but you don’t quite want to touch it. At times like these, you might want a temp gun on hand to get a good reading, like the one [Arnov Sharma] built.

The build is a relatively simple one, and is based around an Waveshare ESP32 C6 development module that comes with a small LCD screen out of the box. The microcontroller is set up to read an MLX90614 infrared temperature sensor. This device picks up the infrared energy that is emitted by objects relative to their temperature. The sensor has a great range—from -70 C to 380 C. The readouts from this sensor are then displayed on the screen. Battery power is from a small 600 mAh LiPo cell, which is managed by a IP5306 charge module.

It’s worth noting that these infrared temperature sensors aren’t infallible devices. The temperature they perceive is based on certain assumptions about factors like an objects emissivity. Thus, they don’t always give accurate readings on metallic or shiny objects, for example. It’s also important to understand the sensor’s field of view. Despite many commercial versions featuring a laser pointer for aiming, many of these infrared temperature sensors tend to average their reading over a small spot that gets larger the farther away they are from the object being measured.

Tools like portable temp guns are pretty cheap, but sometimes it’s just fun to build your own. Plus, you usually learn something along the way. Video after the break.

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