Building a one-off prototype is usually pretty straightforward. Find some perfboard and start soldering, weld up some scrap metal, or break out the 3D printer. But if you’re going to do a production run of a product then things need to have a little more polish. In [Eric Strebel]’s case this means saving on weight and material by converting a solid molded part into something that is hollow, with the help of some lasagna.
What [Eric] walks us through in this video is how to build a weep mold. First, the solid part is cast in silicone. Using the cast, some “sheet clay” is applied to the inside which will eventually form the void for the new part’s walls. The clay needs to be flush with the top of the mold, though, and a trick to accomplish this task is to freeze the mold (next to the lasagna) which allows the clay to be scraped without deforming.
From there, the second half of the mold is poured in, using special channels that allow the resin to “weep” out of the mold (hence the name). This two-part process creates a much more efficient part with thin walls, rather than the expensive solid prototype part.
[Eric] is no stranger around these parts, either. He’s an industrial designer with many tips and tricks of the profession, including a method for building a machining tool out of a drill press and a vise as well as some tips for how to get the most out of a low-volume production run of a product you might be producing.
Continue reading “Using Lasagna to Make Cost-Saving Molds”
[Jim Merullo] and his son were enjoying a nice game of Frisbee when an unfortunate dive led to an injury. His son broke his pinky finger leaving doctors no choice other than bounding his entire left hand in an unreasonably large cast. For most, this would mean no use of the left hand for several weeks, which is somewhat problematic if your son has a Minecraft addiction. [Jim], however, is no stranger to the hacker community and began working on a solution. He broke out the #2 Philips screwdriver, fired up the soldering iron and got to work.
A detailed analysis of the injured left hand revealed limited use of the middle and ring finger, and full use of the thumb. Because his son played the game using his right hand for the mouse and left for the keyboard, he needed to find a way for him to operate a keyboard with the limited use of his left hand. He took apart an old USB keyboard and soldered up some tactile switches to emulate the needed key presses. After making a fashionable Altoids tin mount that fit over the cast, his son was able to enjoy his favorite video game with limited interruption.
Continue reading “Broken Finger Is No Obstacle to Modern Hacker”
A little over a year ago I had a semi-gruesome accident; I stepped off of a ladder and I caught my wedding ring on a nail head. It literally stripped the finger off the bone. This was in spite of me being a safety-freak and having lived a whole second life doing emergency medicine and working in trauma centers and the like. I do have trauma center mentality which means, among other things, that I know you can’t wind the clock back.
A few seconds make an incredible differences in people’s lives. Knowing that it couldn’t be undone, I stayed relaxed and in the end I have to say I had a good time that day as I worked my way through the system (I ended up in a Philadelphia trauma center with a nearby hand specialist) as I was usually the funniest guy in the room. Truth be told they ask incredibly straight questions like”are you right handed?” “Well I am NOW”.
So now I could really use a bit of a body hack, having seen the X-Finger on Hackaday long before I knew that I would one day work with them, I was hoping that we could get one to work for me. In speaking with a couple of the mechanical engineers on the Hackaday staff we decided to get [James Hobson] and [Rich Bremer] involved and that the best way to do it was to get a casting of my injured hand out to them.
Continue reading “[Bil’s] Quest for a Lost Finger: Episode I”
If you follow Instructables.com, it might seem like every third article lately is about Sugru, the nifty air-drying silicone putty that’s good for all manner of repairs and custom parts. It’s fantastic stuff (and we love their slogan, “Hack things better”), but one can’t (yet!) just drop in on any local hardware store to buy a quick fix…so [mikey77] has cooked up a recipe for a basic Sugru work-alike. His “Oogoo” (a name likely inspired by oobleck) is a simple mix of corn starch and silicone caulk.
A two-ingredient recipe would hardly seem adequate material for an article, but [mikey77]’s left no stone unturned, providing an extensive tutorial not only on mixing the compound, but how to add colors, cast and carve custom shapes, and how his home-made recipe compares to the name brand product. As a bonus, the article then drifts into a little Halloween project where he demonstrates etching conductive cloth, how to make conductive glue, and other hands-on shenanigans.