A Scratch-Built Drill Press Vise From Scrap

August 29, 2018 by Dan Maloney 12 Comments

Never underestimate the importance of fixturing when you’re machining parts. No matter what the material, firmly locking it down is the key to good results, and may be the difference between a pleasant afternoon in the shop and a day in the Emergency Room. Flying parts and shattered tooling are no joke, but a lot of times quality commercial solutions are expensive and, well, commercial. So this scratch-built drill press vise is something the thrifty metalworker may want to consider.

To be sure, [Ollari’s] vise, made as it is almost completely from scrap angle iron, is no substitute for a vise made from precision ground castings. But it’s clear that he has taken great care to keep everything as square and true as possible, and we give him full marks for maximizing his materials. And his tools — nothing more complicated than a MIG welder is used, and most of the fabrication is accomplished with simple hand tools. We like the way he built up sturdy profiles by welding strap stock across the legs of the angle iron used for the jaws, to give them a strong triangular cross-section to handle the clamping force. And using the knurled end of an old socket wrench as the handle was inspired; we’ll certainly be filing that idea away for a rainy day in the shop. Although we might use Acme rather than plain threaded rod.

We always enjoy seeing someone fabricate their own tools, and this one reminds us a bit of the full-size bench vise built up from layers of welded steel we featured a while back. It even looks a little like this 3D-printed vise, too.

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A CNC Woodworking Tool That Does The Hard Parts

August 28, 2018 by Kerry Scharfglass 26 Comments

Drawn along in the wake of the 3d printing/home shop revolution has been the accessibility of traditional subtractive CNC equipment, especially routers and mills. Speaking of, want a desktop mill? Try a Bantam Tools (née Othermachine) Desktop Milling Machine or a Carvey or a Carbide 3D Nomad. Tiny but many-axis general purpose mill? Maybe a Pocket NC. Router for the shop? Perhaps a Shapeoko, or an X-Carve, or a ShopBot, or a… you get the picture. [Rundong]’s MatchSticks device is a CNC tool for the shop and it might be classified as a milling machine, but it doesn’t quite work the way a more traditional machine tool does. It computer controls the woodworker too.

At a glance MatchSticks probably looks most similar to a Pocket NC with a big Makita router sticking out the side. There’s an obvious X-axis spoilboard with holes for fixturing material, mounted to a gantry for Z-axis travel. Below the big friendly handle on top is the router attached to its own Y-axis carriage. The only oddity might be the tablet bolted to the other side. And come to think of it the surprisingly small size for such an overbuilt machine. What would it be useful for? MatchSticks doesn’t work by processing an entire piece of stock at once (that what you’re for, adaptable human woodworker) it’s really a tool for doing the complex part of the job – joinery – and explaining to the human how to do the rest.

The full MatchSticks creation flow goes like this:

Choose a design to make on the included interface and specify the parameters you want (size, etc).
The MatchSticks tool will suggest what material stocks you need, and then ask you to cut them to size and prepare them using other tools.
For any parts which require CNC work the tool will help guide the user to fixture the stock to its bed, then do the cutting itself.
Once everything is ready for final assembly the MatchSticks will once again provide friendly instructions for where to pound the mallet.

In this way [rundong], [sarah], [jeremy], [ethan], and [eric] were able to build a much smaller machine tool without sacrificing much practical functionality. It’s almost software-like in it’s focus on a singular purpose. Why reinvent what the table saw can do when the user probably already has access to a table saw that will cut stock better? MatchSticks is an entire machine bent around one goal, making the hard stuff easier.

It’s worth noting that MatchSticks was designed as an exploration into computer/human interaction for the ACM Conference on Human Factors in Computing Systems so it’s not a commercial product quite yet (we’re eagerly waiting!). For a much more in depth look at the project and its goals and learnings the full research paper is available here. Their intro video is down after the break.

Thanks [ethan] for the tip!

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See The Fabulous Workmanship In This Smart Pressure Regulator

August 28, 2018 by Donald Papp 8 Comments

For many projects that require control of air pressure, the usual option is to hook up a pump, maybe with a motor controller to turn it on and off, and work with that. If one’s requirements can’t be filled by that level of equipment and control, then it’s time to look at commercial regulators. [Craig Watson] did exactly that, but found the results as disappointing as they were expensive. He found that commercial offerings — especially at low pressures — tended to leak air, occasionally reported incorrect pressures, and in general just weren’t very precise. Out of a sense of necessity he set out to design his own electronically controlled, closed-loop pressure regulator. The metal block is a custom manifold with valve hardware mounted onto it, and the PCB mounted on top holds the control system. The project logs have some great pictures and details of the prototyping and fabrication process.

This project was the result of [Craig]’s work on a microfluidics control system, conceived because he discovered that much of the equipment involved in these useful systems is prohibitively expensive for small labs or individuals. In the course of developing the electronic pressure regulator, he realized it could have applications beyond microfluidics control, and created it as a modular device that can easily be integrated into other systems and handle either positive or negative pressure. It’s especially well-suited for anything with low air requirements and a limited supply, but with a need for precise control.

3D Printing A Printing Press

August 26, 2018 by Jenny List 3 Comments

If you move among artists, you may have encountered a few printmakers. They create a drawing by cutting through a wax layer that has been deposited on a sheet of copper, then etching the plate and removing the wax. Ink is then rolled onto the plate and cleaned from the flat surface, remaining in the cracks created by the etching. A print is made by putting inked plate and a sheet of paper through a roller press at significant pressure, squeezing the ink from the cracks onto the paper. The result is a beautiful print, but the press required to do the job is by no means cheap.

[Martin Schneider] has addressed this expense with his Open Press project, by producing a printmaking press that can be 3D-printed for a fraction of the outlay of a traditional press. It’s by no means a large model, but appears no less functional for it.

The form of the press is straightforward enough, with a print bed that is drawn between a pair of rollers by a rack-and-pinion gear, and as you would imagine the construction is quite substantial. It’s all CC licensed, and you can make one for yourself if you would like, by downloading the files from Thingiverse.

It’s fair to say that printmaking hasn’t appeared much here, but we can see this press could have significant use beyond artistic applications. Meanwhile it’s a great example of 3D printing providing the means to reduce the barrier to entry for something that was previously quite an expensive pursuit.

UnMaker 2.0 Is Wile E Coyote’s Dead Blow Hammer

August 25, 2018 by Lewin Day 13 Comments

Hammers! They’re good for knocking in nails, breaking things apart, and generally smashing up the joint, if you’re in such a mood. Typically, they’re made of iron or steel and come in a variety of sizes depending on the purpose — from tiny chipping hammers for delicate sculpture work, to the heavy-duty sledge for tearing through building materials. But what if you built your own comically large mallet? Enter UnMaker 2.0.

The hammer receiving an eye-catching lick of paint.

Basically, it’s a really big hammer. It’s vaguely reminiscent of a dead blow type design, in that it consists of a moderately shock-absorbing outer shell filled with heavier material. In this case, steel ball bearings find a home inside the shell made out of maple and with a traditional tapered handle. In many ways it’s quite a typical build — other than the fact of its gigantic size and 34-pound head weight. Both of these make it a shoe-in for the ACME catalog. That roadrunner won’t know what hit him.

[Kevin] reports that it is not so much “swung” as it is “raised and allowed to drop”, due to its impressive weight. Clearly, it packs a punch. It’s a solid follow-on from the group’s former work – a truly gigantic utility knife.

Simulate PIC And Arduino/AVR Designs With No Cloud

August 22, 2018 by Al Williams 17 Comments

I’ve always appreciated simulation tools. Sure, there’s no substitute for actually building a circuit but it sure is handy if you can fix a lot of easy problems before you start soldering and making PCBs. I’ve done quite a few posts on LTSpice and I’m also a big fan of the Falstad simulator in the browser. However, both of those don’t do a lot for you if a microcontroller is a major part of your design. I recently found an open source project called Simulide that has a few issues but does a credible job of mixed simulation. It allows you to simulate analog circuits, LCDs, stepper and servo motors and can include programmable PIC or AVR (including Arduino) processors in your simulation.

The software is available for Windows or Linux and the AVR/Arduino emulation is built in. For the PIC on Linux, you need an external software simulator that you can easily install. This is provided with the Windows version. You can see one of several videos available about an older release of the tool below. There is also a window that can compile your Arduino code and even debug it, although that almost always crashed for me after a few minutes of working. As you can see in the image above, though, it is capable of running some pretty serious Arduino code as long as you aren’t debugging.

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Measure Resistance The Colourful Way

August 22, 2018 by Jenny List 30 Comments

One of the first things anyone with an interest in electronics learns is the resistor colour code. The colour of the first band reveals the first figure, the second the subsequent figure, and the third a power-of-ten multiplier. At first you learn these colours, but eventually you just recognise the values through familiarity. You don’t have to think about multipliers when you see orange-orange-red, you just know that it’s a 3K3 resistor.

[Plusea] has come up with an entertaining interface for an ohmmeter, which instead of displaying the resistance on an LCD or a meter shows it as the colours of the code, via a set of addressable LEDs. The work is done by an ATtiny85 microcontroller, and the whole thing is mounted on a flexible PCB (fabrication of which is itself interesting, placing cut copper traces on a sheet of kapton and covering with a second kapton layer cut to be the solder mask). There is even a clever integration of a CR2032 battery holder from the PCB itself, though they admit that it could be made more compact with the use of SMD components instead of through-hole.

The write-up and associated photo album tells us a lot about the project, but is missing a crucial detail: a shot of it working. We’ll give them the benefit of the doubt on that front though, because we like the idea and its execution.

Strangely, this isn’t the first ohmmeter to use the resistor colour code in this way, we’ve previously brought you one featuring a light-up giant resistor.