Tool Hacks

2961 Articles

Building An Affordable Press For Heat Set Inserts

September 9, 2020 by 11 Comments

If you’re building mechanical assemblies with 3D printed parts, you’ll quickly realize that driving machine screws into thermoplastic isn’t exactly an ideal solution. It can work in a pinch, but you can easily strip the threads if you crank down too hard. The plastic holes can also get worn down from repeated use, which is a problem if you’re working on something that needs to be taken apart and reassembled frequently. In those situations, using brass heat set inserts gives the fasteners something stronger to bite into.

You can install these inserts by hand, but if you plan on doing a lot of them, a dedicated press station like the one [Chris Chimienti] recently put together will save you a lot of aggravation in the long run. In the video after the break he walks viewers through the design and use of the device, which itself relies on a number of 3D printed parts using the very same inserts it’s designed to install.

The spring-loaded arm can slide up and down the extrusion to adjust for height.

To build this tool you’ll need a piece of aluminum extrusion, some smooth rod, a couple springs, and an assortment of fasteners. Nothing that wouldn’t likely be in the parts bin of anyone who’s been tinkering with 3D printers for awhile, though even if you had to buy everything, the Bill of Materials will hardly break the bank. For the base you can use a piece of scrap wood, though [Chris] has opted to make it a storage compartment where he can store the inserts themselves. We really like this approach, but obviously you’ll need to have access to woodworking tools in that case.

Clearly shopping on the top shelf, [Chris] purchased a kit that actually came with a Weller soldering iron and the appropriate tips for the various sized inserts. If you’re like us and just buy the inserts that come in a plastic baggie, you may need to adapt the arm to fit your iron of choice. That said, the idea of having a dedicated iron that you can leave mounted in the press makes a lot of sense to us if you can swing it.

[Joshua Vasquez] wrote up a phenomenal guide to getting started with heat set inserts last year that’s an absolute must-read for anyone interested in the concept. Whether you build a dedicated press or just push them in freehand, his tips and tricks will help insure you get the best result possible.

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Measure 1024 Times, Cut Once

September 8, 2020 by 25 Comments

Typically, someone’s first venture into coding doesn’t get a lot of attention. Then again, most people don’t program a CNC table saw right out of the gate. [Jeremy Fielding] wasn’t enticed with “Blink” or “Hello, world,” and took the path less traveled. He tackled I/O, UX, and motion in a single project, which we would equate to climbing K2 as a way to get into hiking. The Python code was over 500 lines, so we feel comfortable calling him an over-achiever.

The project started after he replaced the fence on his saw and wondered if he could automate it, and that was his jumping-on point, but he didn’t stop there. He automated the blade height and angle with stepper motors, so the only feedback is limit switches to keep it from running into itself. The brains are a Raspberry Pi that uses the GPIO for everything. There is a manual mode so he can use the hand cranks to make adjustments like an ordinary saw, but he loses tracking there. His engineering background shines through in his spartan touchscreen application and robust 3D model. The built-in calculator is a nice touch, and pulling the calculations directly to a motion axis field is clever.

We’ve covered [Jeremy]’s DIY dynamometer and look forward to whatever he builds next. Until then, check out a light-duty approach to CNC that cuts foam in two-and-a-half dimensions.

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Play A Game Of Multimeter

September 5, 2020 by 4 Comments

There are many different single board computers that are general purpose, but there’s another breed targeted at specific applications. One such is the Clockworkpi, a handheld Game Boy-style games console, which may be aimed at gamers but has just as much ability to do all the usual SBC stuff. It’s something [UncannyFlanigan] has demonstrated, by turning the Clockworkpi into a multimeter. And it’s not just a simple digital multimeter either, it’s one that sports graphing as well as instantaneous readings.

At its heart is an Arduino board that supplies the analogue to digital conversion, with opto-couplers for isolation between the two boards. A simple three-way switch selects voltage, current, and resistance ranges, and the ClockworkPi interface is written in Python. We can see that this could easily be extended using the power of the Arduino to deliver more functionality, for which all the code is handily available in a GitHub repository. It’s not a perfect multimeter yet because it lacks adequate input protection, but it shows a lot of promise.

If you’re intrigued by this project then maybe you’ll be pleased to know that it’s not the first home made multimeter we’ve featured.

An Arduino Controller For Hot Air Handles

September 4, 2020 by 3 Comments

In general, the cost of electronic components and the tools used to fiddle with them have been dropping steadily over the last decade or so. But there will always be bargain-hunting hackers who are looking to get things even cheaper. Case in point, hot air rework stations. You can pick up one of the common 858D stations for as little as $40 USD, but that didn’t keep [MakerBR] from creating an Arduino controller that can be used with its spare handles.

Now to be fair, it doesn’t sound like price was the only factor here. After all, a spare 858D handle costs about half as much as the whole station, so there’s not a lot of room for improvement cost-wise. Rather, [MakerBR] says the Arduino version is designed to be more efficient and reliable than the stock hardware.

The seven wires in the handle connector have already been mapped out by previous efforts, though [MakerBR] does go over the need to verify everything matches the provided circuit diagrams as some vendors might have fiddled with the pinout. All the real magic happens in the handle itself, the controller just needs to keep an eye on the various sensors and provide the fan and heating element with appropriate control signals. An Arduino Pro Mini is more than up to the task, and a custom PCB makes for a fairly neat installation.

This isn’t the first time we’ve seen somebody replace the controller on one of these entry-level hot air stations, but because there are so many different versions floating around, you should do some careful research before cracking yours open and performing a brain transplant.

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A 3D Printed Magnetic Stirrer For Your DIY Chemistry Projects

September 3, 2020 by 20 Comments

When mixing or agitating delicate solutions in the chemistry lab, a magnetic stirrer is often the tool of choice. They’re able to be easily sterilized and cleaned, while maintaining isolation between the mechanical parts and the solutions in question. While they can be purchased off the shelf, [Max Siebenschläfer] whipped up a design that can easily be built at home.

The build consists of a 3D printed base, containing a simple brushed motor. This is hooked up to a motor controller fitted with a simple potentiometer for adjusting the speed of rotation. The motor is then fitted with a small 3D printed spinner containing two magnets. A similar 3D printed part acts as a stirrer, and is fitted with a matching pair of magnets, and dropped into the solution. The magnets in the stirrer are attracted to the ones on the end of the motor, and so when the motor spins, the stirrer spins in the solution, with no physical contact required.

It’s a simple way to build a magnetic stirrer at home without having to shell out big money for a laboratory grade unit. We imagine this could be put to fun use for stirring coffee or cocktails, too – if built with a food-grade spinner. More advanced designs are also possible for the eager home scientist. Video after the break.

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Flipper Zero Blasts Past Funding Goal And Into Our Hearts

September 2, 2020 by 22 Comments

There’s never been a better time to be a hardware hacker: the tools are cheap, the information is free, and the possibilities are nearly endless. But that doesn’t mean there isn’t room for improvement. The Flipper Zero was developed to make the world of hardware hacking even more accessible, and as of this writing, has officially ended its Kickstarter campaign after raising a staggering $4.8 million. To say the community is excited about this little gadget is perhaps an understatement.

So what does the Flipper Zero do that’s gotten everyone so worked up? Well, for one, it’s not so much what it can do as how it does them. Taking inspiration from the already popular pwnagotchi project, the Flipper Zero gamifies the normally rather mundane tasks of sniffing for 433 MHz signals and flashing EEPROMs with the addition of an animated dolphin that’s sustained by your hacking. If you want the little fellow to grow and be happy, you need to keep poking and prodding around at any piece of hardware you come across.

If you’re looking for a comprehensive list of features, that’s a little harder to nail down. Partially because the device has picked up a number of new tricks (such as support for Bluetooth and NFC) thanks to the fact it made better than 8,000% of its original funding goal, but also because it can be expanded with additional hardware and software which obviously won’t get developed until the community gets their hands on the core device.

But even the core functionality, demonstrated in the video after the break, is quite compelling. The Flipper Zero’s CC1101 transceiver chip (anyone else thinking of the IM-ME right now?) allows it to record, analyze, and play back RF signals from 300 to 928 MHz, meaning you can instantly take over remote control systems that aren’t using a rolling code for authentication. It can also read and emulate many different RFID cards, record and transmit IR signals, emulate a USB HID device and run programmable payloads, and act as a USB to UART/SPI/I2C adapter. All contained in a sleek and pocket-sized enclosure that looks like a proper cyberpunk hacking gadget.

We’re extremely interested in seeing what the community can do with the Flipper Zero, especially now that the extra windfall has allowed the team to create a formal Developer Program for people who want to help work on the core platform or produce add-on modules. After banking nearly $5 million, this will be the yardstick by which all other crowd sourced hacking gadgets are measured for years to come; let’s hope they make it count.

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