An Improved Bed And Custom Wasteboard For A CNC Router

[Adam Haile] has been spending some time improving his CNC router and his latest change is a custom wasteboard with improved bed support. Not only does the MDF wasteboard have plenty of threaded inserts to make for easy clamping solutions, but [Adam] replaced the frame underneath the board with a new set of aluminum extrusions to provide better support. Originally, there was only support for the edges of the wasteboard, which allowed the middle to sag. While researching the machine’s specs, he was able to recognize and order the exact extrusions he needed from Misumi and construct an improved bed to go with the new board. Should you wish to make your own version, [Adam] provides all the part numbers and CAD files required.

Embedded below is a video showing the machine drilling the holes, followed by surfacing the entire board so that it is flat. Since the bolt heads are well below the surface of the board, and the threaded inserts for the holes are on the bottom, there’s no worry of the tool hitting anything it shouldn’t during this process.

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Casting The Bed Of A CNC Machine In Granite

If you’re looking at CNC machines, or machine tools in general, heavier is better. That old drill press or mill made of a few hundred pounds of cast iron isn’t just better because it’s stood the test of time for a hundred years — greater mass equals less vibration. Thanks to modern epoxy resins, we now have a replacement for tons and tons of iron. Epoxy granite, or chips of granite bound together with epoxy resin, is a viable and very good base for CNC machines, mills, and other tools that are served well with a ton of mass. [Joerg Beigang] is building his own CNC router, and he’s building the base out of epoxy granite. Here’s how he’s doing it.

Before you pour epoxy into a mold, you’ll need to figure out how you’re going to attach your ways, linear rails, and ball screws. [Joreg] is bolting these parts to pieces of aluminum he cut on his home made panel saw before carefully drilling and tapping them to accept the linear rails. These aluminum plates were then mounted to the bottom panel of the mold, in this case melamine-coated plywood.

As you would expect, the most intricate part of this build isn’t globbing up a mold with epoxy resin. No, the real trick here is making sure the rails of the CNC are aligned perfectly before the epoxy goes in. This was done by bolting the linear rails to the mold box and checking everything with a dial indicator. Once that was done it was time to pour.

The bed itself is made of 18kg of epoxy granite, with the entire pour done in four batches. The best way to settle a big pour of epoxy granite is through vibration, just like concrete, but it looks as though [Joreg] is getting some good results by tamping it down with a few sticks. You can check out the first part of this build series below.

If we’ve captured your interest, it’s worth reminding you that this isn’t the first epoxy granite CNC machine we’ve featured.

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CNC Turns a Single PCB into Origami Hemisphere

Trying to make a hemispherical surface out of a PCB is no easy feat. Trying to do that and make the result a working circuit is even harder. Doing it with one solid piece of FR4 seems impossible, right?

Not so much. [brainsmoke] came up with a clever way to make foldable, working PCBs that can be formed into hemispheres. The inspiration for this came from a larger project that resulted in a 32-cm diameter LED-studded sphere, which a friend thought would make a swell necklace if it was scaled down. That larger sphere was made somewhat like a PCB soccer ball, with individual panels soldered together. [brainsmoke] didn’t relish juggling dozens of tiny PCBs to make a necklace-sized version, so the unfolded pattern for half a deltoidal hexecontahedron was laid out as one piece on single-sided FR4. The etched boards were then cut out on a CNC mill, with the joints between the panels cut as V-grooves from the rear of the board. By leaving just enough material to act as a live hinge, [brainsmoke] was able to fold the pattern up into a hemisphere while leaving the traces intact. The process was fussy and resulted in a lot of broken FR4 and traces, but with practice and the use of thicker board material and heavier copper, the hemisphere came together. The video below shows the final product

This objet d’art is [brainsmoke]’s entry in the Circuit Sculpture Contest, which is just wrapping up wrapped up last week. We can’t wait to share some of the cool things people came up with in this contest, which really seemed to get the creative juices flowing.

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Salvaging an Ancient, Dangerous Machine With Wood

What do you do when you have a gigantic old drum sander with a bent table? Scrapping it will give you a few cents per pound, but this machine is just too cool, and would be too useful to just throw away. That’s when inspiration strikes. To fix this old machine, [Frank Howarth] built a new bed for an old drum sander out of wood.

The machine in question is a Frank H. Clement Surface Sanding Machine from the early part of the 20th century. This machine is basically a 30 inch long, 14 inch diameter drum that’s wrapped in sandpaper. There are removable tables for this machine, and basically what we’re looking at here is a jointer that can handle 30-inch wide boards, only it’s a sander. [Frank] picked up this machine way back in 2015 from a friend for free, but everything has a cost. There’s a problem with this sander: one of the previous owners stored a heavy jointer on the table, and the hefty iron bed was bent down in the middle. This makes the vintage surface sanding machine absolutely useless for anything. A new bed would have to be constructed.

[Frank] is a master craftsman, though, and he has enough scrap wood sitting around to build just about anything. After taking some careful measurements of the frame of the sander, he cut and glued up a few large panels of a glueLam beam, salvaged from an earlier operation. This beam is tremendously strong, and resawing and gluing it up into a panel produced a very hefty board that’s perfect for the bed of a gigantic, ancient surface sanding machine.

The actual fabrication of the new bed happened on [Frank]’s CNC router. The bottom of the bed was easy enough to fit to the cast iron frame, but there was an issue: because these tables are meant to butt up against a spinning drum, [Frank] needed to cut away a cove underneath the table. A CNC router can easily do this, but apparently the glueLam beam couldn’t handle it — a bit of the edge split off. These panels are basically made of glue, though, and some quick action with a few clamps saved the project.

The bed for this sander is now done, and a change in the pulley brought the speed of the drum down to something reasonable. Of course, this is a woodworking machine from the early 1900s, and safety was a secondary concern. We’re not worried, though. [Frank] still has all his fingers. A guard for the belt is in the works, though.

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Putting More Tech Into More Hands: The Robin Hoods of Hackaday Prize

Many different projects started with the same thought: “That’s really expensive… I wonder if I could build my own for less.” Success is rewarded with satisfaction on top of the money saved, but true hacker heroes share their work so that others can build their own as well. We are happy to recognize such generosity with the Hackaday Prize [Robinhood] achievement.

Achievements are a new addition to our Hackaday Prize, running in parallel with our existing judging and rewards process. Achievements are a way for us to shower recognition and fame upon creators who demonstrate what we appreciate from our community.

Fortunately there is no requirement to steal from the rich to unlock our [Robinhood] achievement, it’s enough to give away fruits of price-reduction labor. And unlocking an achievement does not affect a project’s standings in the challenges, so some of these creators will still collect coveted awards. The list of projects that have unlocked the [Robinhood] achievement will continue to grow as the Hackaday Prize progresses, check back regularly to see the latest additions!

In the meantime, let’s look at a few notable examples that have already made the list:

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Motorized Mini Excavator Rises From Sheets of Plywood

Fathers of Hackaday, we’ve got bad news — you’ve been out-fathered. Behold the mechanism of your undoing: a working miniature excavator, executed in plywood.

To be fair, the rules of the game have changed lately. Time was when a nipper would ask for the impossible, and we dads would never have to deliver. But with CNC routers, 3D-printing, and industrial-grade CAD software you can use for free, the possibility hurdle is getting ever shorter. Still, when his son put in this request, [Alex Lovegrove] really delivered. Everything on this excavator works, from tracks to boom to bucket. There are hundreds of parts, mostly machined from plywood but with a smattering of 3D-printed gears and brackets. The tracks and slew gear are powered by gear motors, while linear actuators stand in for hydraulic rams on the boom. The videos below show the machine under test and the unbearable cuteness of it being loved.

Hacker parents need not despair, of course. There’s plenty of room left for your imagination to run amok. For inspiration, check out this working railway system, or any of the several backyard roller coasters we’ve featured.

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Rolling Around A 4th Axis

[Perry] was interested in adding a 4th axis to his CNC machine, but not very excited at the prospect of spending hundreds of dollars on the parts and electronics to make it work. There is a very clever and very inexpensive way to add a 4th axis to a CNC machine, though, and after a bit of fabrication, he was able to add a ‘rolling’ 4th axis to his machine.

[Bob]’s ‘rolling’ 4th axis.
The idea for this build comes from [Bob] over on the CNC Shark forums. Instead of adding a motor to rotate a work piece around, [Bob]’s build simply mounts it between two jaws, and rolls everything around against the bed of the CNC router. Don’t have a clue what that means? Check out the picture to the right, and you’ll see brilliance built in Delrin and HDPE.  By mounting two rack gears to the bed and two geared jaws to the carriage of the machine, moving the router in the Y axis also rotates the 4th axis. This is far, far too clever; it doesn’t require any additional electronics and the only software tweaks are a bit of G-code hacking.

[Perry] took one look at [Bob]’s project and decided this would be the perfect build to get him a 4th axis. The parts for this build were fabricated out of black HDPE, with the only real change to the design being a ‘variable length’ 4th axis. Instead of two rack gears mounted to the bed of the machine, [Perry]’s build only uses one rack, with the other end simply rolling on the bed.

There are a lot of clever inventions that don’t work, so what’s the verdict with this CNC hack? It actually looks pretty good. [Perry] was able to turn some square stock into round stock, and able to engrave a spiral around a cylinder. You can check out those videos below.

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