Measuring Sharpie Thickness… The Ink Itself, Not The Pen!

April 20, 2020 by Mike Szczys 29 Comments

How we missed this one from a few years ago is unknown, but we’re glad to catch up with it now. Have you ever needed to measure how thick the ink in a Sharpie line is? Of course you haven’t. But if you needed to, how would you do it? Using a wicked-sensitive indicator gauge and levering an interesting test setup.

[Tom] from [oxtoolco] got his hands on a tool that measures in 1/10,000,000th (that’s one ten-millionth) increments and was wondering what kind of shenanigans you can do with this Lamborghini of dial indicators. It’s one thing to say you’re going to measure ink, but coming up with the method is the leap. In this case it’s a gauge block — a piece of precision ground metal with precise dimensions and perfectly perpendicular faces. By zeroing the indicator on the block, then adding lines from the Sharpie and measuring again, you can deduce the thickness of the ink markings.

After arraying diagonal lines on the gauge block it is placed lines-down under the dial indicator. This distributes the ink layer across a larger area, as probing the ink line directly would likely result in inaccurate readings. On that topic the gauge block is moved using pliers, as introducing heat from your fingers could result in expansion of the metal upsetting the readings.

The results? Black, blue, and red Sharpie were all tested, alongside blue and black Dykem layout fluid. Ten samples of each were run and the readings were all very close, save a couple of obvious outliers. Clocking in the thinnest is black Sharpie at about 118 millionths of an inch (~30 microns) and blue Dykem was the thickest at 314 millionths (86 microns). [Tom] quips that since we now know the thickness, you could even use ink as a shim.

If you can’t get enough Sharpie in your life, try it as an extremely satisfying add-on for your plasma cutter.

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Gain An Understanding Of Injection Molding’s Design Gotchas

April 19, 2020 by Donald Papp 11 Comments

When it comes to manufacturing, sheet metal and injection molding make the world go ’round. As a manufacturing method, injection molding has its own range of unique design issues and gotchas that are better to be aware of than not. To help with this awareness, [studiored] has a series of blog posts describing injection molding design issues, presented from the perspective of how to avoid and address them.

Design of screw bosses demonstrating conflict between molder’s guidelines and vendor’s recommendations. Compromising between both is a science and an art.

Because injection molding involves heat, warp is one issue to be aware of and its principles will probably be familiar to anyone with nitty-gritty experience in 3D printing. Sink marks are also an issue that comes down to differential cooling causing problems, and can ruin a smooth and glossy finish. Both of these play a role in how best to design bosses.

Minimizing and simplifying undercuts (similar to overhangs in 3D printer parlance) is a bit more in-depth, because even a single undercut means much more complex tooling for the mold. Finally, because injection molding depends on reliably molding, cooling, and ejecting parts, designing parts with draft (a slight angle to aid part removal) can be a fact of life.

[studiored] seems to have been working overtime on sharing tips for product design and manufacture on their blog, so it’s worth keeping an eye on it for more additions. We mentioned earlier that much of the manufacturing world revolves around injection molding and sheet metal, so to round out your knowledge we published a primer on everything you need to know about the art and science of bending sheet metal. With a working knowledge of the kinds of design issues that affect these two common manufacturing methods, you’ll have a solid foundation for any forays into either world.

Perfect Wire Hose Clamps With A Simple DIY Tool

April 17, 2020 by Danie Conradie 31 Comments

Hose clamps have been around as long as we’ve been using flexible hoses. Usually, a clamp consists of a slotted metal strap, and a screw for tightening. Most of us know how quickly they slip when you want to add a bit more torque, or the frustration of not having the right size. Fortunately [Max Egorov] reminded us of DIY wire clamps (video after the break), an excellent alternative that is very effective, covers an infinite size range and is easy to make with a simple tool.

The wire clamp is in effect a doubled girth hitch, that is pulled tight with the ends bent over to keep the tension. [Max] shows you how to easily make your own clamper tool with basic tools and a few bits of steel. Making it as ornate as his one is definitely not required. You can also buy a commercial tool that is sold under the name ClampTite, which uses a leadscrew type design.

To achieve a tight seal with a hose clamp, the main requirement is constant pressure around its entire circumference. These wire clamps do this very well and are popular among aircraft mechanics, since flying in a plane with a leaky coolant or fuel hose could shorten your lifespan a bit. [Max] also demonstrates a variety of other uses for these including fixing tool handles and even building a ladder.

We love simple but effective tools like this, and we’ll definitely be adding one to our toolbox. Have you used these before? Let us know in the comments!

There is (almost) never such a thing as too many tools, and making your own is very satisfying. We’ve seen people build an outfit a complete carpentry workshop using plywood, and build sheet metal press brake with no welding.

Thanks [Keith O] for the tip!

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Oscilloscope And Microscope Augmented With Ghosts

April 3, 2020 by Bryan Cockfield 13 Comments

Augmented reality saw a huge boom a few years ago, where an image of the real world has some virtual element layer displayed on top of it. To get this effect to work, however, you don’t need a suite of software and smart devices. [elad] was able to augment a microscope with the output from an oscilloscope, allowing him to see waveforms while working on small printed circuit boards with the microscope.

The build relies on a simplified version of the Pepper’s Ghost illusion. This works by separating two images with a semi-transparent material such as glass, placed at an angle. When looking through the material, the two images appear to blend together. [elad] was able to build a box that attaches to the microscope with a projection of the oscilloscope image augmented on the view of the microscope.

This looks like it would be incredibly useful for PCBs, especially when dealing with small SMD components. The project is split across two entries, the second of which is here. In one demonstration the oscilloscope image is replaced with a visual of a computer monitor, so it could be used for a lot more applications than just the oscilloscope, too. There aren’t a lot of details on the project page though, but with an understanding of Pepper’s Ghost this should be easily repeatable. If you need more examples, there are plenty of other builds that use this technique.

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Designing Printed Adapters For Power Tool Batteries

March 30, 2020 by Tom Nardi 26 Comments

Unless you’re particularly fond of having multiple types of batteries and chargers, you’d do well to make sure all your portable power tools are made by the same company. But what do you do if there’s a tool you really need, but your brand of choice doesn’t offer their own version of it? Rather than having to buy into a whole new tool ecosystem, you might be able to design your own battery adapter.

Note the locking tab that’s been printed separately.

As [Chris Chimienti] explains in the video after the break, the first thing you’ve got to do (beyond making sure the voltages match) is take some careful measurements of the connectors on your batteries and tools. His goal was to adapt a Milwaukee M12 battery to Makita CXT tool, so if you happen to have that same combination of hardware you can just use his STLs. Otherwise, you’ll be spending some quality time with a pair of calipers and a notepad.

Once the interfaces have been designed and printed, they are wired together and mounted to opposite ends of the center support column. In theory you’d be done at this point, but as [Chris] points out, there’s a bit more to it than just wiring up the positive and negative terminals. Many tools use thermistors in the batteries for thermal protection purposes, and when the tool doesn’t get a reading from the sensor, it will likely refuse to work.

His solution to the problem is to “hotwire” the thermistor lead on the battery connector with a standard resistor of the appropriate value. This will get the tool spinning, but obviously there’s no more thermal protection. For most homeowner DIY projects this probably won’t cause a problem, but if you’re a pro who’s really pushing their tools to the limit, this project might not be for you.

Of course, this isn’t the first time we’ve seen somebody adapt batteries from different brands to work on their tools. It’s a common enough problem once you start building up a workshop, although you could always avoid it by building all your own tools.

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Vinyl Cutter Migrates From Scrapbooks To Gaskets

March 30, 2020 by Sonya Vasquez 15 Comments

We know it all too well: another smoothly-operating night in the garage easily halted by a broken component. In the late hours of the night, no hardware store will open its doors. And while waiting may reward the patient, creativity may reward those who act now. That’s exactly where [Justin] found himself one evening: with a torn gasket. Not to be dismayed, he turned to his fiancee [Amy] and the two of them managed to design and cut a perfectly fitting replacement gasket on [Amy’s] vinyl cutter in a mere matter of minutes.

In the video after the break, the two step us through their process in detail. By starting with an image of the existing gasket, they capture a reference image. Some light work in photoshop cleans up everything except the resulting gasket they’re looking for. Finally, sizing “by eye” in the vinyl cutter’s software after measuring an existing dimension gives them sufficient precision to remake a duplicate gasket that’s eye-for-eye indistiguishable from the original.

It seems like we often hear about vinyl-cut gaskets in passing or in the comments, but it’s great to see a team post such a fabulous success story putting them to good use. And in case a plain old’ vinyl cutter blade wont do the trick, why not try running it at ultrasonic speeds?

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Custom Drill Press Table Eliminates Hassles

March 29, 2020 by Bryan Cockfield 7 Comments

Getting a perfect workshop together, with all the right tools, is a dream for many. A lot of us cobble together what we can with a dremel tool, a soldering iron, and whatever work surface happens to be available in the kitchen or spare bedroom. But even when we finally get a permanent garage or shop to work in, there are still some challenges to overcome with our workspaces. [Workshop From Scratch] was having issues with his drill press, and solved them with this custom build.

Rather than modify an existing press, he first welded a table together from scratch using square tube. From there he set about solving those issues. The first was having to make a large number of adjustments up and down when working on larger pieces. For that he added an electrically adjustable worktop which keeps him from having to make constant adjustments of the press itself. The second improvement over the standard press workspace was adding a cooling system for the cutting tools, saving himself money in bits and allowing quicker drilling.

The finished product looks professional thanks to a quality paint job and, of course, having all the right tools in the workshop in the first place to put something like this together. We all have an idea in our heads about the perfect workshop for our own needs, but don’t forget to think outside the box when it comes to building one yourself.

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