Two types of polymer clay hand warmers with a digital temperature controller.

Adjustable Electric Hand Warmers

It may be the last gasp of summer here in the Northern Hemisphere, but it’s always cold somewhere, whether it’s outdoors or inside. If you suffer from cold, stiff hands, you know how difficult it can be to work comfortably on a computer all day. Somehow, all that typing and mousing does little to warm things up. What you need are hand warmers, obviously, and they might as well be smart and made to fit your hands.

Using a heat gun to cure polymer clay. Fifteen-year-old [Printerforge] created these bad boys in an effort to learn how to code LCDs and control heat like Magneto controls ferrous metals. Thanks to digital control, they can heat up to specific temperatures, and they happen to run for a long time.

Power-wise, these warmers use a 18650 cell and a TP4056 charging module. Everything is controlled by an Arduino Nano, which reads from both a thermistor and a potentiometer to control the output.

[Printerforge] really thought this project through, as you’ll see in the Instructable. There’s everything from a table of design requirements to quick but thorough explanations of nichrome wire and basic electronic theory.

And then there’s the material consideration. [Printerforge] decided that polymer clay offers the best balance of heat conductivity and durability. They ended up with two styles — flat, and joystick grip. The best part is, everything can fit in a generous pocket.

Clay is good for a lot of things, like making the perfect custom mouse.

Slab Casting – A New Way To Combine 3D Printing And Ceramics

Slip casting can be messy both in processing and in making the original plaster mold. What if there was a better way, thanks to 3D printing?

[Allie Katz] has developed a new technique using 3D printed slab molds to make ceramics. By combining the ability of 3D printing to make intricate designs and the formability of clay, they have found a way to make reproducible clay objects without all that tedious mucking about with liquid clay.

[Katz] takes us through a quick “Mould Making 101” before showing how the slab casting press molds were made. Starting with a positive CAD design, the molds were designed to eliminate undercuts and allow for air infiltration since a plastic mold can’t suck the water out of the clay like a plaster one would. Some cookie clay cutters were also designed to help with the trickier bits of geometry. Once everything was printed, the molds were coated with cornstarch and clay was pressed in. After removal, any final details like handles can be added and the pieces are then fired as normal.

If you’d like to see some more 3D printing mixed up with ceramics, check out 3D printing glass with a laser, reliable ceramic slurry printing, or this TPU-based approach.

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3D Printing With Clay, Thanks To Custom Extruder

When it comes to 3D printing clay, there are a lot of challenges to be met. An extruder capable of pushing clay is critical, and [davidsfeir] has an updated version suitable for an Ender 3 printer. This extruder is based on earlier designs aimed at delta printers, but making one compatible with an Ender 3 helps keep things accessible.

Lightly pressurized clay comes in via the clear tube. Air escapes out the top (motor side) while an auger homogenizes the clay and pushes it out the nozzle.

What’s special about a paste extruder that can push clay? For one thing, clay can’t be stored on a spool, so it gets fed into the extruder via a hose with the help of air pressure. From there, the clay is actually extruded with the help of an auger that takes care of pushing the clay down through the nozzle. The extruder also needs a way to deal with inevitable air bubbles, which it does by allowing air to escape out the narrow space at the top of the assembly while clay gets fed downward.

[davidsfeir] was greatly inspired by the work of clay-printing pioneers [Piotr Waśniowski] and his de-airing clay extruder, and [Jonathan Keep], who has documented 3D printing with clay comprehensively in a freely-available PDF. You can check out more of [david]’s designs on his Instagram page.

There are so many different aspects to printing with clay or clay-like materials that almost every part is ripe for innovation. For example, we’ve seen wild patterns result from sticking a thumping subwoofer under a print bed.

Extrusion For The Pottery Shop

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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Retrotechtacular: Clay Pipe The Hard Way

Troll YouTube long enough and chances are good that you’ll come across all kinds of videos of the “How It’s Made” genre. And buried in with the frying pans and treadmills and dental floss manufacturers, there no doubt will be deep dives on how pipe is made. Methods will vary by material, but copper, PVC, cast iron, or even concrete, what the pipe factories will all have in common is the high degree of automation they employ. With a commodity item like pipe, it’s hard to differentiate yourself from another manufacturer on features, so price is about the only way to compete. That means cutting costs to the bone, and that means getting rid of as many employees as possible.

Such was not always the case, of course, as this look at how Irish Stoneware & Fireclays Ltd. made clay pipe, drain tiles, and chimney flues back in the 1980s shows. The amount of handwork involved in making a single, simple piece of clay pipe is astonishing, as is the number of hands employed at the various tasks. The factory was located in Carrickmacross, County Monaghan, Ireland, near an outcropping of shale that forms the raw material for its products. Quarrying the shale and milling it into clay were among the few mechanized steps in the process; although the extrusion of the pipe itself was also mechanized, the machines required teams of workers to load and unload them.

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a variety of enclosure options

The Many Ways To Solve Your Enclosure Problems

Most projects around here involve some sort of electronics, and some sort of box to put them in. The same is true of pretty much all commercially available electronic products as well.

Despite that, selecting an enclosure is far from a solved problem. For simple electronics it’s entirely possible to spend more time getting the case just right than working on the circuit itself. But most of the time we need to avoid getting bogged down in what exactly will house our hardware.

The array of options available for your housing is vast, and while many people default to a 3D printer, there are frequently better choices. I’ve been around the block on this issue countless times and wanted to share the options as I see them, and help you decide which is right for you. Let’s talk about enclosures!

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Clay Pot MP3 Player Whipped Up With The Freedom-K64F

In the streaming era, few of us think about MP3s on a day to day basis anymore. Our music collection is managed by warring executives in streaming companies from far-off lands. However, for [vinod], they’re still useful — seeing as he just built himself an MP3 player that fits in a clay pot.

The build is based on the FRDMK64F development board, packing a powerful 120 MHz ARM chip. This has enough grunt to decode MP3s on the fly, using the Helix MP3 decoder library. The MP3s themselves are streamed off an SD card, using the faster SDIO access method rather than relying on slower SPI. Once decoded, the resulting PCM audio data is shifted out via a DAC using the chip’s DMA hardware, allowing for smooth, glitch-free playback. Output to a big woofer is via a 15 W class D amplifier, with the whole rig powered from a USB powerbank.

With all the electronics piled on the back of a big woofer speaker with lashings of hot glue, the final result is quite imposing; all the more so when installed neatly inside a clay pot acting as a bass reflex enclosure. We’ve seen some concrete cast speakers before, but not nearly enough hacker projects in clay. Please rectify this, and inform us once you’ve done so. Thanks in advance — video after the break!

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