Cheap, Resourceful DIY Mini CNC Router/Mill Contraption

February 12, 2014 by Rich Bremer 10 Comments

Few Hackaday Readers would disagree with the classic phrase: Necessity is the mother of invention. That statement is certainly no exaggeration when it comes to this mini 3-axis CNC Machine. The builder, [Jonathan], needed a way to prototype circuit boards that he designed. And although he admittedly doesn’t use it as much as he intended, the journey is one of invention and problem solving.

[Jonathan] started from the ground up with his own design. His first machine was a moving gantry style (work piece doesn’t move) and ended up not performing to his expectations. The main problem was alignment of the axis rails. Not becoming discouraged, [Jonathan] started on version 2. This time around the work piece would move in the X and Y directions like a conventional vertical milling machine. The Porter-Cable laminate trimmer would move up and down for the Z axis. It is clear that the frame is built specifically for this project. Although not the prettiest, the frame is completely functional and satisfactorily stiff for what it needs to do.

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Hack A Mag-Lite To Be Rechargeable

February 9, 2014 by Marsh 10 Comments

rechargeMaglite

Most tools sport rechargeable batteries these days, but there’s no need to toss that old flashlight: just replace the cells with rechargable ones!

[monjnoux] had a 3-cell D-sized MagLite lying around—though you could reproduce this hack with a 2 to 5 cell model—which he emptied of its regular batteries and replaced with some 11000mAh NiMHs from eBay. The original bulb was also tossed in favor of a 140-lumens LED.

After disassembling the flashlight, [monjnoux] set about installing the new parts. He replaced the original bulb with the LED, soldering it into place and securing it with hot glue. He then drilled a hole in the body of the flashlight for a DC socket. The charger he purchased is adaptive, detecting the number of cells and adjusting its voltage accordingly. It had the wrong connector, though, so [monjnoux] simply chopped off the end and soldered on a new one. For a hack that comes in at 40€, it’s definitely a cheaper alternative to the official rechargeable model: which costs 80€. And with a duration of 7 hours (though it’s unclear whether this number reflects continuous use), it likely outlasts the official model, as well.

Behold Lil’ Screwy, A Homebrew 100-Ton Press

February 8, 2014 by Kristina Panos 76 Comments

Here we have a magnificent example of the power of the inclined plane. [Chris] has built Lil’ Screwy, a 100-ton home-built press for about $35 plus scrap on hand. He demonstrates its frightening power by punching a 17-mm hole through 8mm-thick steel using an Allen key.

As [Chris] explains in his hilarious video waiting for you after the jump, the force comes from using really big screws. Lil’ Screwy uses four 1-inch L7-rated ready rods with eight threads to the inch. The bolts run between two 1″ steel plates to form the press. In the top plate, he drilled 1″ holes. The bottom holes are drilled out 7/8″ and tapped so the two plates clamp together with awesome crushing power when you twist the giant coupling nuts.

[Chris] milled a pocket in the underside of the top plate for a big neodymium magnet that will keep, for instance, a 17-mm Allen key in place while you punch a piece of steel with it. He has a ring of smaller ones embedded into the bottom plate to hold supports in place for broaching.

As a special bonus, [Chris] shows you how to stick it to the man when it comes to using that last bit of Never-Seez in the can, and also how to make your decals temporarily repositionable.

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A USB Connected Box-o-Encoders

February 4, 2014 by Adam Fabio 27 Comments

picoscope-encoder

[Colin] loves his PicoScope, a USB based “headless” oscilloscope. While using it he found himself longing for a classic oscilloscope interface. Mouse clicks just weren’t a replacement for grabbing a dial and twisting it. To correct the situation he created his USB-Connected Box-o-Encoders. The box maps as a USB keyboard, so it will work with almost any program.

[Colin] started by finding encoders. There are plenty of choices – splined or flatted shaft, detents or no detents, panel, PCB, or chassis mount. He settled on an encoder from Bourns Inc. which uses an 18 spline shaft. His encoder also includes a push button switch for selection. With encoders down, knobs were next. [Colin] chose two distinct styles. The two knob styles aren’t just decorative. The user can tell which row of knobs they are on by touch alone. Electronics were made simple with the use of a Teensy++ 2.0. [Colin] used a ATUSBKey device running Teensy software, but says the Teensy would have been a much better choice in terms of size and simplicity.

Once everything was wired into the box, [Colin] found his encoders would “spin” when the knobs were turned. They are actually designed to be PCB mounted, and then screwed into a control panel. Attempts to tighten down the panel mounting nut resulted in a broken encoder. Rather than redesign with purely panel mounted encoders, [Colin] used a dab of epoxy to hold the encoder body in place.

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Soldering In The Dark — Add Some Light To Your Iron!

February 3, 2014 by James Hobson 33 Comments

iron_01

While [William] may not know what he’s doing (his words, not ours!), at least he can SEE what he’s doing now with this awesome soldering iron light modification. And judging by the build quality, we’d reckon he really does know what he’s doing!

He’s taken a piece of copper-clad PCB, and formed it to create a nice circular copper donut. This allows him to make a ring of LEDs in parallel that will slide nicely over the soldering iron and integrate into the plastic case.

To power it, he’s made a small diode bridge to rectify the AC, and a 24 ohm high-wattage resistor run in series with the heating element. The voltage drop across the resistor is 7.5V max, which equates to about 5.3V RMS minus the diode voltage drops. This means the LEDs see about 4.5V at a total of 135mA, which works out to about 17mA each — just under the approved rating. All of this fits nicely into the original casing of the soldering iron.

Finally to finish it off, he’s MacGyver’d an old pill bottle into a protective casing around the LED ring — it looks surprisingly stock on the soldering iron!

Do you have a tool hack that adds handy features? Let us know through the Tips Line!

Collin’s Lab Is Coming Back

February 3, 2014 by Todd Harrison 30 Comments

We would like to share a bit of good news; Collin’s Lab is back on the airwaves of the Internet. If you didn’t know, [Collin Cunningham] previously created excellent short videos, sometimes entertainingly tongue-in-cheek, for Make Magazines on the subjects of electronic components and fundamental electronics. In 2012 he was hired at Adafruit as a Creative Engineer to help with software development and video production.

Going forward Collin’s Lab videos will be a regular feature on Adafruit’s Blog and their YouTube channel. We’re sure there is going to be tons of entertaining learning from Collin with his unique video production skills and presentation delivery.

This first release of Collin’s Lab on Adafruit is a primer review covering fundamental multimeter functionality and measurements. Not much here for the medium to advanced electronics hacker but for the beginner this is an excellent and quick way to learn the basics on using your multimeter.

If you want to checkout Collin’s older video productions you can find them on his Narbotic Instruments site under – “Make Presents” and “Collin’s Lab” or watch them all with this convenient playlist. Just after the break you can also watch his latest edition of Collin’s Lab.

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[CNLohr] Demos His Photoetch PCB Process

January 31, 2014 by Brian Benchoff 25 Comments

etch

If you’re going to learn something, it only makes sense to learn from a master. [CNLohr] is known around these parts for his fablous PCBs, and he’s finally started to document his entire fabrication process.

[CNLohr] is using a photoetch process, where a mask is created with a laser printer on overhead transparencies. He covers the copper clad boards with a Riston photosensitive mask—available here, and they accept Bitcoin—sent through a laminator, and exposed with the laser printed mask and a UV grow bulb. After the mask has developed, [CNLohr] drops his boards into a ferric chloride bath that eats away the unexposed copper. He then removes the photomask with acetone and cuts the boards with a pair of aircraft snips, and they’re ready to be soldered up with components.

Yes, home PCB etching tutorials are pretty much a solved problem, but [CNLohr]’s work speaks for itself. He’s also the guy who made a microcontroller/Linux/Minecraft thing on a glass microscope slide. Learning from a guy with these skills means you’re learning from one of the best.

Video below, and there’s also a video going over the design of a PCB using KiCAD (!) and TopoR (!!!) available here.

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