Making A Hammer With Beautiful Engravings

March 5, 2019 by Lewin Day 19 Comments

Tools are a key part of any maker’s pursuit of their work. For most of us, our tools come from the local hardware store or are purchased online. Some prefer to craft their own, however, and [Uri Tuchman] is just one such person.

[Uri] starts at the absolute beginning, with a piece of unfinished rectangular stock. The workpiece is marked up, and the shape of the hammer head meticulously filed out by hand. The wooden handle is similarly prepared from raw stock with a combination of planes, chisels and files.

It may not be the fastest way to work, but careful hand craftsmanship is always impressive to watch. The build also showcases [Uri]’s talent at engraving, with the complex designs all carved out of the surface a millimeter at a time. [Uri] recommends enamel paint to highlight such works, for its rich color and the ease of removing excess paint.

Where [Uri] has built a beautiful piece of art that moonlights as a hammer, it’s possible to go in completely the opposite direction with a build. Video after the break.

[Thanks to BrightBlueJim for the tip!] Continue reading “Making A Hammer With Beautiful Engravings” →

CNC Your Own PCB With This Tutorial

March 3, 2019 by Al Williams 26 Comments

It is getting so easy to order a finished printed circuit board that it is tough to justify building your own. But sometimes you really need a board right now. Or maybe you need a lot of fast iterations so you can’t wait for the postal service. [Thomas Sanladerer] shows how he makes PCBs with a CNC machine and has a lot of good advice in the video below.

He starts with Eagle, although, you could use any creation package. He shows what parameters he changes to make sure the traces don’t get eaten away and how to do the CAM job to get the files required to make the boards. If you don’t use Eagle, you’ll need to infer how to do similar changes and get the same kind of output.

We’ve only heard a few people pronounce Gerber (as in Gerber file) with a soft G sound, but we still knew what he meant. We have the same problem with GIF files. However, once you have Gebers, you can join the video’s workflow about 5 minutes in.

At that point, he uses FlatCAM to convert the Gerbers to a single G-code file that integrates the paths and drill files. There were a few tricks he used to make sure all the tracks are picked up. Other tricks include leveling a spoil board by just milling it down and mounting different size bits. He also has ideas on aligning the Z axis.

Continue reading “CNC Your Own PCB With This Tutorial” →

Digital Protractor Makes Angular Measurements A Snap

March 3, 2019 by Lewin Day 7 Comments

Old school vernier calipers served engineers and machinists well for a long time — and did a perfectly good job. Digital models then came along and were easier to read. They now rule the roost, despite their thirst for batteries. Humans are naturally wired to make the least effort possible at all times. That’s why you always drive to the store that’s only a few blocks from your doorstep. In this vein, you may find a digital protractor preferable to the classic printed type.

[Nirav Jadav]’s project is a simple one but serves as a good learning experience for those getting to grips with microcontrollers. An Arduino Pro Mini serves as the brains, reading signals from an MPU6050 gyroscope. Measured angles are displayed on a small OLED screen.

To use the protractor, first the reference button must be pressed, then the device may be rotated to measure the angle. Relying on a gyroscope means that it’s likely less accurate than a printed device, particularly if it isn’t recalibrated every few measurements to account for drift.

However, like many projects to grace these pages, its value lies not in its usability, but in the journey of creation. To build such a device requires programming ability, an understanding of interfacing with external peripheral devices, as well as how to drive a graphical display. These skills are highly useful in a wide variety of projects, and they’ll serve [Nirav] well in projects to come.

Once you’ve built your digital protractor, why not have a stab at building a digital measuring tape?

[Thanks to Baldpower for the tip!]

Programmable Ruler Keeps 1970’s Computing Alive

March 2, 2019 by Tom Nardi 23 Comments

A ruler seems like a pretty simple device; just a nice straight piece of material with some marks on it. There are some improvements out there to the basic design, like making it out of something flexible or printing a few useful crib notes and formulas on it so you have a handy reference. But for the most part, we can all agree that ruler technology has pretty much plateaued.

Well, not if [Brad] has anything to say about it. His latest creation, the Digirule2, is essentially an 8-bit computer like those of the 1970’s that just so happens to be a functional ruler as well. Forget lugging out the Altair 8800 next time you’re in the mood for some old school software development, now you can get the same experience with a piece of hardware that lives in your pencil cup.

Even if you’ve never commanded one of the blinkenlight behemoths that inspired the Digirule2, this is an excellent way to get some hands-on experience with early computer technology. Available for about the cost of a large pizza on Tindie, it represents one of the easiest and most cost-effective ways to tell your friends that as a matter of fact you have programmed a computer in binary.

The Digirule2 is powered by a Microchip PIC18F43K20, and is programmed by punching binary in one byte at a time with a bank of eight tactile switches. To make things a little easier, programs can be saved to the internal EEPROM and loaded back up just as easily thanks to the handy buttons next to the power switch. Now all you’ve got to do is figure out what all those blinking LEDs mean, and you’ll be in business.

The original Digirule was a logic gate simulator that we first covered back in 2015. We’re always happy to see projects grow and evolve over time, and think this new retro-computer themed variant is going to be quite popular with those who still love toggle switches and blinking lights.

Continue reading “Programmable Ruler Keeps 1970’s Computing Alive” →

The Easiest Thermal Camera Build You’ll Ever See

March 1, 2019 by Tom Nardi 41 Comments

Thermal cameras are one of those tools that we all want, but just can’t justify actually buying. You don’t really know what you would do with one, and when even the cheap ones are a couple hundred dollars, it’s a bit out of the impulse buy territory. So you just keeping waiting and hoping that eventually they’ll drop to the price that you can actually own one yourself.

Well, today might be the day you were waiting for. While it might not be the prettiest build, we think you’ll agree it can’t get much easier than what [vvkuryshev] has put together. His build only has two components: a Raspberry Pi and a thermal camera module he picked up online for about $80 USD. There isn’t even any wiring involved, the camera fits right on the Pi’s GPIO header.

Of course, you probably wouldn’t be seeing this on Hackaday if all he had to do was just buy a module and solder it to the Pi’s header. As with most cheap imported gadgets, the GY-MCU90640 module that [vvkuryshev] bought came with some crusty Windows software which wasn’t going to do him much good on the Raspberry Pi. But after going back and forth a bit with the seller, he was able to get some documentation for the device that put him on the right track to writing a Python script which got it working under Linux.

The surprisingly simple Python script reads a frame from the camera four times a second over serial and run it through OpenCV. It even adds some useful data like the minimum and maximum temperatures in the frame to the top of the image. Normally the script would output to the Pi’s primary display, but if you want to use it remotely, [vvkuryshev] says he’s had pretty good luck running it over VNC. In fact, he says that with a VNC application on your phone you could even use this setup on the go, though the setup is a bit awkward for that in its current incarnation.

This isn’t the first DIY thermal camera build we’ve seen, and it isn’t even the first one we’ve seen that leveraged a commercially available imaging module. But short of buying a turn-key camera, we don’t see how it could get any easier to add heat vision to your bag of tricks.

Vacuum-Powered Rotary Tool Redux, This Time Machined

February 28, 2019 by Dan Maloney 18 Comments

We love to see projects revisited, especially when new materials or methods make it worth giving the first design another go around. This twin-turbine vacuum-powered Dremel tool is a perfect example of what better tools can do for a build.

You may recall [JohnnyQ90]’s first attempt at a vacuum powered rotary tool. That incarnation, very similar in design to the current work, was entirely 3D-printed, and caused no little controversy in the comments about the wisdom of spinning anything made on an FDM printer at 43,000 RPM. Despite the naysaying, [Johnny] appears to have survived his own creation. But the turbo-tool did have its limitations, including somewhat anemic torque. This version, machined rather than printed and made almost completely from aluminum, seems to have solved that problem, perhaps thanks to the increased mass of the rotating parts. The twin rotors and the stator were milled with a 5-axis CNC machine, which has been a great addition to [JohnnyQ90]’s shop. The turbine shaft, looking like something from a miniature jet engine, was meticulously balanced using magnets mounted in the headstock and tailstock of a lathe. The video below shows the build and a few tests; we’re not big fans of the ergonomics of holding the tool on the end of that bulky hose, but it sure seems to work well. And that sound!

We first noticed [JohnnyQ90] when he machined aluminum from soda cans to make a mini Tesla turbine. His builds have come a long way since then, and we look forward to what he’ll come up with next.

Continue reading “Vacuum-Powered Rotary Tool Redux, This Time Machined” →

Inside The Secret World Of Crimping

February 28, 2019 by Eric Evenchick 34 Comments

At some point in your electrical pursuits, you’ll need to make a connector. Maybe you’re designing something that will connect to another device, or maybe the spaghetti mess of wires coming out of your Raspberry Pi has become a pain to deal with. Whatever the reason, a proper connector can solve a lot of headaches in electronics projects.

Your first thought might be to run to your favorite component distributor and order the connectors, terminals, and crimping tool. Unfortunately, those tools can cost thousands of dollars. Maybe you’ll just solder the connectors instead? Don’t! It makes for easily damaged connections.

Fortunately, [Matt Millman] has a great guide on wire-to-board connectors. This guide will explain why you should never solder crimp terminals and then get into working with some of the most common wire-to-board connector families.

For example, the Mini-PV series (which often get called “Dupont”) are one of the most ubiquitous connectors in hobbyist electronics. They’re the connector on those rainbow colored jumper wire sets, and connect perfectly to 0.1″ pin headers. The connectors and terminals are cheap, but the official HT-0095 crimp tool costs over $1500. Most crimp tools make a mess of these terminals since they require a cylindrical jaw to crimp correctly. By using a combination of two unofficial tools, you can crimp these connectors properly for under $60.

If you want to learn more about the art of wiring, the NASA Workmanship Standards are an interesting read.

[Thanks to MarkMLl for the tip!]