open hardware textile spinning machine constructed from aluminium extrusions, arduino electronics and 3D printed parts

An Open Hardware Automatic Spinning Machine

January 21, 2023 by Dave Rowntree 6 Comments

The team at the Berlin-based Studio HILO has been working on ideas and tools around developing a more open approach to small-scale textile production environments. Leveraging open-source platforms and tools, the team has come up with a simple open hardware spinning machine that can be used for interactive yarn production, right on the desktop. The frame is built with 3030 profile aluminium extrusions, with a handful of 3D printed, and a smidge of laser cut parts. Motion is thanks to, you guessed it, NEMA 17 stepper motors and the once ubiquitous Arduino Mega 2560 plus RAMPS 1.4 combination that many people will be very familiar with.

The project really shines on the documentation side of things, with the project GitLab positively dripping with well-organised information. One minor niggle is that you’ll need access to a polyjet or very accurate multi-material 3D printer to run off the drive wheel and the associated trailing wheel. We’re sure there’s a simple enough way to do it without those tools, for those sufficiently motivated.

We liked the use of Arduino for the firmware, keeping things simple, and in the same vein, Processing for the user interface. That makes sending values from the on-screen slider controls over the USB a piece of cake. Processing doesn’t seem to pop up on these pages too often, which is a shame as it’s a great tool to have at one’s disposal. On the subject of the user interface, it looks like for now only basic parameters can be tweaked on the fly, with some more subtle parameters needing fixing at firmware compilation time. With a bit more time, we’re sure the project will flesh out a bit more, and that area will be improved.

Of course, if you only have raw fibers, that are not appropriately aligned, you need a carder, like this one maybe?

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Extrusion For The Pottery Shop

January 20, 2023 by Bryan Cockfield 2 Comments

Extrusion is a process for forming materials by forcing them through an opening, which can allow for complex shapes. Aluminum extrusion beams are what most of us are probably thinking of, but plenty of other things are made from extruded material like pipe, heat sinks, and even macaroni. Extrusion can also be used for modelling clay to create uniform sections of rounded clay as a starter material for producing other pottery, and [Justins Makery] has built a custom extruder to do just that.

The build starts with welding together a metal frame to hold the press, and uses a wooden wagon handle to drive the extruder. The handle can be moved up or down the frame to increase the range of motion thanks to a custom bearing and slots cut into the frame’s post. The piston mechanism itself is built out of aluminum plate with a cylinder loosely fitted to it to allow for easy cleaning, and the top of the piston uses a loose-fitting plastic cap cut out of an old cutting board.

With everything in pace, the extruder can make cylinders of clay of any desired thickness thanks to swappable dies. While it doesn’t produce the end result of the workshop directly, it definitely helps to provide the potter with clay of uniform dimensions used for building other pieces of pottery, much like how aluminum extrusions are used to build all kinds of other things as well.

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One-Size-Fits-All Wrench Points To A Nut Job

January 17, 2023 by Anool Mahidharia 37 Comments

When [Hand Tool Rescue] came across a 1919 patent for a one size fits all wrench, he couldn’t help but recreate it. Described in the patent as “a new, original, ornamental design for a wrench”, the wrench had a slot for possibly every fastener that the inventor could think of. Not only did it have slots for several hexagonal fasteners, but many others for octagonal, square and even a pentagonal fastener.

[Hand Tool Rescue] reckons there are 47 slots for various sizes and types of fasteners, not counting the ones whose purpose he could not fathom. Just in case he missed any fastener sizes, the original designer decided to add an alligator wrench at the other end of the handle, potentially negating the need for any of the other slots. The tool even features a sharp edge along one of the sides, possibly for use as a scraper of some kind.

Why such a crazy design was patented, or what were the functions of some of its slots are questions that will likely remain unanswered. At best, we can all take guesses at solving the mystery of this tool. [Hand Tool Rescue] scales the original drawing such that one of the slots has a width of 1 inch, and then uses that as a template to recreate the wrench. He starts with a slab of 3/8th inch thick, grade 4140 steel, which has a high strength to weight ratio and can be case hardened after machining, making it suitable for this ornamental project.

He then embarks on his journey of excessive milling, drilling, filing, band sawing and shaping (using a slotting attachment), totaling about 11 hours worth of drudgery. Of course, one could argue that it would have been much easier, and accurate, to have used modern machining methods. And we are spoilt for choices here among laser cutting, water jet cutting or even EDM machining, any of which would have done the job faster, cleaner and more precisely. But we guess [Hand Tool Rescue] wanted to stick to traditional methods as would have been available in 1919 to an inventor who wanted to make a prototype of his awesome, all in one wrench.

If you can help explain the overall function of this wrench, or identify some of the more vague slots in it, then [Hand Tool Rescue] would be happy to get the feedback. And talking about less desirable wrenches, check out how this Sliding Wrench Leaves a Little to be Desired.

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DIY Magnet Handling Tool Puts An End To Placement Errors

January 14, 2023 by Donald Papp 10 Comments

I’m sure we can all agree that the worst time to find out a magnet is the wrong way around is after glue has been applied. With that in mind, [erick.siders] created the parametric Magnet Placer tool.

Color-coded tools, one for each polarity.

Picking up and placing magnets into assemblies can be an error-prone process, because magnet polarity cannot be directly identified or sensed by either sight or fingertips. This tool helps by acting a lot like a suction pickup tool — press the plunger down, and a magnet can be picked up, release the plunger, and the magnet lets go. Simple, and effective.

Since the tool is polarity-dependent (depending on which orientation the pickup magnet is mounted into the internal plunger), [erick.siders] suggests printing two tools and color-coding them. That way, one can choose the right tool based on the situation and be confident that the magnets are right-side-up, every time.

The tools use a long metric bolt, a magnet, and a spring, but none of those parts are particularly critical. We also love the way that the end result has no gaps or openings into the moving parts, which means nothing can get caught on or inside anything during use or storage.

It’s a parametric design and the CAD files (in both Fusion 360 and STEP flavors) are provided, so modification should be a breeze. And if you happen to be using PrusaSlicer, remember you can now drop STEP format files directly in for slicing.

An All-Billet, Single-Piece, Flexure-Based Nutcracker

January 11, 2023 by Lewin Day 22 Comments

Typical nutcrackers rely on simple pin hinges to join two handles for the cracking task. However, [adam the machinist] has demonstrated that a single-piece nutcracker is possible by using the flexural properties of the right grade of steel.

The nutcracker is manufactured out of 17-4 PH stainless steel, heat treated to the H900 condition. A flexural spring section at the top of the nutcracker takes the place of the usual hinge, allowing the handles to be squeezed together and the teeth of the cracker to open the nut. Machining the flexural section is first achieved with a series of CNC drill operations on the billet stock, before regular milling is used to shape the rest of the spring section and tool. The video dives deep into the finer points of the CNC operations that produce such a great finish on the final part. It even covers the use of a tiny scissor jack to help hold the handles still during machining.

The result is a highly attractive and desirable nutcracker that looks far more special than the regular fare you might pick up at Walgreens. The all-billet tool is a nutcracker very much fit for a sci-fi set. We’ve seen some other kitchen tools around here before, too, albeit of more questionable utility.

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Printable Case For Pinecil And TS100 Soldering Irons (Mis)Uses A 608 Bearing

January 7, 2023 by Donald Papp 61 Comments

[PjotrStrog]’s rugged Pinecil / TS100 storage case is the perfect printable accessory to go with a hacker’s choice of either the Pine64 Pinecil, or the Miniware TS100 soldering irons. There are some thoughtful features beyond just storing the iron, too!

A standard 608 bearing makes for a handy heat-resistant stand.

Some of you may have spotted a 608 bearing in the image above, and might be wondering what it is for. In proud hacker tradition of using things for something other than their intended purpose, the bearing makes a heat-resistant stand to hold the iron while in use.

This design has a pretty deep history that illustrates the value of sharing one’s designs and allowing others to remix and refine ideas. [PjotrStrog]’s work makes use of the earlier and highly thoughtful TS100, Pinecil, TS80 & TS80p cases with options by [Termiman], which themselves are based on bearing-equipped TS100 case by [Olvin] that we covered back in 2020.

We loved the Pine64 Pinecil soldering iron, and this looks like a fantastic printable storage and carry option. There are a few pieces of hardware needed to put the rugged version together, but [PjotrStrog] also offers a less rugged design with fewer hardware needs, so check that out as well.

Excuse Me, Your Tie Is Unzipped

January 5, 2023 by Al Williams 102 Comments

If you ask your typical handyperson what’s the one thing you need to fix most things, the answer might very well be duct tape. But second place — and first place in some circles — would have to be zip ties. These little wonders are everywhere if you look for them. But they are a relatively recent invention and haven’t always had the form they have today.

The original zip tie wasn’t called a zip tie or even a cable tie. In 1958 they were called Ty-Raps and produced by a company called Thomas and Betts. Originally meant to improve aircraft wiring harnesses, they found their way into various electronic equipment and packaging uses. But they’ve also become helpful in very unusual places too. A policeman trying to round up rioters would have problems carrying more than a few conventional handcuffs. But flexible cuffs based on zip ties are lightweight and easy to carry. Colon surgeons sometimes use a modified form of zip tie during procedures.

History

Maurus Logan worked for the Thomas and Betts company. In 1956, he was touring an aircraft manufacturing plant. Observing a wiring harness being put together on a nail board, similar to how car harnesses are made, he noted that the cables were bundled with waxed twine or nylon cord. A technician had to tie knots in the cord, sometimes cutting their fingers and often developing calluses. In addition, the twine was prone to fungal growth, requiring special treatment.

Logan kept turning the problem over in his mind and tried various approaches. By 1958, he had a patent for the Ty-Rap. The tie was lightweight, easy to install, easy to remove, and inexpensive.

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