Laser Cutting Wooden Pogo Pin Test Jigs

June 25, 2019 by Tom Nardi 10 Comments

Now as far as problems go, selling so many products on Tindie that you need to come up with a faster way to test them is a pretty good one to have. But it’s still a problem that needs solving. For [Eric Gunnerson] the solution involved finding a quick and easy way to produce wooden pogo test jigs on his laser cutter, and we have a feeling he’s not the only one who’ll benefit from it.

The first step was exporting the PCB design from KiCad into an SVG, which [Eric] then brought into Inkscape for editing. He deleted all of the traces that he wasn’t interested in, leaving behind just the ones he wanted to ultimately tap into with the pogo pins. He then used the Circle tool to put a 0.85 mm red dot in the center of each pad.

You’re probably wondering where those specific parameters came from. The color is easy enough to explain: his GlowForge laser cutter allows him to select by color, so [Eric] can easily tell the machine to cut out anything that’s red. As for the size, he did a test run on a scrap of wood and found that 0.85 mm was the perfect dimensions to hold onto a pogo pin with friction.

[Eric] ran off three identical pieces of birch plywood, plus one spacer. The pogo pins are inserted into the first piece, the wires get soldered around the back, and finally secured with the spacer. The whole thing is then capped off with the two remaining pieces, and wrapped up in tape to keep it together.

Whether you 3D print one of your own design or even modify a popular development board to do your bidding, the test jig is invaluable when you make the leap to small scale production.

Two-Piece Boxes Thanks To Laser-Cut Flex Hinges

April 6, 2017 by Dan Maloney 14 Comments

It sounds like a challenge from a [Martin Gardner] math puzzle from the Scientific American of days gone by: is it possible to build a three-dimensional wooden box with only two surfaces? It turns out it is, if you bend the rules and bend the wood to make living hinge boxes with a laser cutter.

[Martin Raynsford] clearly wasn’t setting out to probe the limits of topology with these boxes, but they’re a pretty neat trick nonetheless. The key to these boxes is the narrow to non-existent kerf left by a laser cutter that makes interference fits with wood a reality. [Martin]’s design leverages the slot and tab connection we’re used to seeing in laser-cut boxes, but adds a living flex-hinge to curve each piece of plywood into a U-shape. The two pieces are then nested together like those old aluminum hobby enclosures from Radio Shack. His GitHub has OpenSCAD scripts to parametrically create two different styles of two-piece boxes so you can scale it up or (somewhat) down according to your needs. There’s also a more traditional three-piece box, and any of them might be a great choice for a control panel or small Arduino enclosure. And as a bonus, the flex-hinge provides ventilation.

Need slots and tabs for boxes but you’re more familiar with FreeCAD? These parametric scripts will get you started, and we’ll bet you can port the flex-hinge bit easily, too.

Slim And Classy Word Clock Shows The Weather Too

April 27, 2016 by Dan Maloney 16 Comments

Word clocks are a neat twist on traditional timepiece user interfaces. Spelling out the time with words and phrases rather than numerals fancies up a clock nicely. And if you add the current weather and forecast to the display, you get this attractive and handy word-based time and weather display.

For this clock, one of the many custom builds on [GMG]’s site that betray a certain passion for unusual timepieces, an 8×32 array of Neopixels lives behind a laser-cut sheet of steam-bent birch plywood. Each pixel is masked by either an alphanumeric character or an icon representing weather conditions. An ESP8266 fetches time and weather data and drives the display serially, controlling the color of each cell and building up the display. The video below shows the clock doing its thing.

Sure, we’ve featured plenty of word clocks before, even some with weather display, but we like the slim and understated design of this build. We’re particularly impressed by the lengths [GMG] took in packing as much capability into the 256-pixel display as possible, like the way “today” and “tomorrow” overlap. And if you’ve got an eye for detail, you might spot what gets displayed when it’s over 80° and 80% relative humidity.

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Wooden Antikythera Mechanism Is Geared For Greatness

April 27, 2016 by Kristina Panos 28 Comments

[Dave] builds custom wooden orreries, which are mechanical models of the solar system. It’s no surprise then that he’s interested in the Antikythera Mechanism—a small geared device discovered off the coast of the Greece in 1900 that is believed to be the first analog computer and one of the oldest known geared systems, built partly to predict the positions of celestial bodies in the solar system as it was understood in ancient Greece.

[Dave] decided to build a wooden version of the Antikythera Mechanism as a proof of concept that it can be done in wood rather than the brass of the original. He also sought to incorporate all the modern theories of the device’s gear train. The entire system is made out of 6mm birch plywood that [Dave] cut by hand on a scroll saw. That’s right — no CNC or lasers here. This has as much to do with replicating the craftsmanship of the original as it does with practicality. Besides, the pitch of the gear teeth is too small to be effectively cut with a laser.

There are no motors, either. The gears are centrally connected to nested brass tubing and the mechanism is actuated with a hand crank. The six pages of forum discussion are worth combing through just to see the pictures of [Dave]’s progress and all of those meticulously hand-cut gears.

It took [Dave] the better part of two years to complete this work of art, and you can see it in motion after the break. With the first version complete, he has begun Mk. II which will feature all of the spiral dials and pointers of the original. If you’re interested in exploring the Antikythera Mechanism further, here is Hackaday’s own in-depth look at it.

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Zelo, The Improbable Wooden Trike

September 1, 2009 by Phil Burgess 11 Comments

The earliest bicycles were made from wood. Nearly two centuries later, some garage tinkerers still turn to this most traditional of materials for their own creations, since welding one requires experience and tools beyond the reach of many. Resembling Gilligan’s Island props, the resulting bikes are both artistic and great fun, but not very practical for real use; often heavy, ill-fitting or lacking durability.

[Boris Beaulant’s] birch laminate Zelo, on the other hand, has cleaner lines than anything you’d see in an IKEA showroom. Not content with an ordinary two-wheeler, he’s tackled a three-wheeled recumbent trike, which requires even finer tolerances. Two months and over 1,300 miles later, the trike is still rolling strong through the French countryside, proving its mettle as legitimate transportation and not just a garage novelty. [Beaulant’s] build log (Google translation here) offers some insights into the development of this masterpiece, starting with prior woodworking projects (furniture, rolling toys and a children’s bike) and finding clever solutions to problems such as creating a mold of his own back for a custom-contoured seat.