Plastic Strips Protect Ball Screws On This Homebrew CNC Router

It’s a fact of life for CNC router owners — swarf. Whether it’s the fine dust from a sheet of MDF or nice fat chips from a piece of aluminum, the debris your tool creates gets everywhere. You can try to control it at its source, but swarf always finds a way to escape and cause problems.

Unwilling to deal with the accumulation of chips in the expensive ball screws of his homemade CNC router, [Nikodem Bartnik] took matters into his own hands and created these DIY telescopic ball screw covers. Yes, commercial ball screw covers are available, but they are targeted at professional machines, and so are not only too large for a homebrew machine like his but also priced for pro budgets. So [Nikodem] recreated their basic design: strips of thin material wound into a tight spring that forms a tube that can extend and retract. The first prototypes were from paper, which worked but proved to have too much friction. Version 2 was made from sheets of polyester film, slippery enough to get the job done and as a bonus, transparent. They look pretty sharp, and as you can see in the video below, seem to perform well.

It’s nice to see a build progress to the point where details like this can be addressed. We’ve been following [Nikodem]’s CNC build for years now, and it really has come a long way.

Continue reading “Plastic Strips Protect Ball Screws On This Homebrew CNC Router”

Complex Wood Joints, Thanks To New Software’s Interactive Features

Artfully-crafted wooden joints that fit together like puzzle pieces and need neither glue nor nails is fascinating stuff, but to call the process of designing and manufacturing them by hand “time-consuming” would be an understatement. To change that, a research team from the University of Tokyo presented Tsugite, a software system for interactively designing and fabricating complex wooden joints. It’s named after the Japanese word for joinery, and aims to make the design and manufacture of glue and fastener-free joints much easier than it otherwise would be.

Three-way joint that requires no glue or fasteners.

It looks like the software is so far only a research project and not something that can be downloaded The software is available on GitHub and the approach it takes is interesting. This downloadable PDF explains how the software deals with the problem of how to make such a task interactive and practical.

The clever bit is that the software not only provides design assistance for the joints themselves in a WYSIWYG (what you see is what you get) interface, but also generates real-time feedback based on using a three-axis CNC tool as the manufacturing method. This means that the system understands the constraints that come from the fabrication method, and incorporates that into design feedback.

The two main limitations of using a three-axis CNC are that the cutting tool can only approach the material from above, and that standard milling bits cannot create sharp inner corners; they will have a rounded fillet the same radius as the cutting bit. Design can be done manually, or by selecting joints from a pre-defined gallery. Once the design is complete, the system generates the toolpaths for manufacture.

Currently, Tsugite is limited to single joints meant for frame structures, but there’s no reason it couldn’t expand beyond that scope. A video to accompany the paper is embedded below, it’s short and concise and shows the software in action, so be sure to give it a look.

Continue reading “Complex Wood Joints, Thanks To New Software’s Interactive Features”

Hackaday Links Column Banner

Hackaday Links: October 11, 2020

If you’re interested in SDR and digital signal processing but don’t know where to start, you’re in luck. Ben Hillburn, president of the GNU Radio Project, recently tweeted about an online curriculum for learning SDR and DSP using Python. The course was developed by Dr. Mark Lichtman, who was a lead on GNU Radio, and from the look of it, this is the place to go to learn about putting SDRs to use doing cool things. The course is chock full of animations that make the concepts clear, and explain what all the equations mean in a way that’s sure to appeal to practical learners.

It’s not much of a secret that the Hackaday community loves clocks. We build clocks out of everything and anything, and any unique way of telling time is rightly applauded and celebrated on our pages. But does the clock motif make a good basis for a video game? Perhaps not, but that didn’t stop Clock Simulator from becoming a thing. To “play” Clock Simulator, you advance the hands of an on-screen clock by pressing a button once per second. Now, thanks to Michael Dwyer, you don’t even have to do that one simple thing. He developed a hardware cheat for Clock Simulator that takes the 1PPS output from a GPS module and wires it into a mouse. The pulse stream clicks the mouse once per second with atomic precision, rendering the player irrelevant and making the whole thing even more pointless. Or perhaps that is the point.

Maybe we were a little hard on Clock Simulator, though — we can see how it would help achieve a Zen-like state with its requirement for steady rhythm, at least when not cheating. Another source of Zen for some is watching precision machining, and more precise, the better. We ran into this mesmerizing video of a CNC micro-coil winder and found it fascinating to watch, despite the vertical format. The winder is built from a CNC lathe, to the carriage of which a wire dispenser and tensioning attachment have been added. The wire is hair-fine and passes through a ruby nozzle with a 0.6 mm bore, and LinuxCNC controls the tiny back and forth motion of the wire as it winds onto the form. We don’t know what the coil will be used for, but we respect the precision of winding something smaller than a matchhead.

Dave Jones over at EEVblog posted a teardown video this week that goes to a place few of us have ever seen: inside a processor module for an IBM System/390 server. These servers earned the name “Big Iron” for a reason, as everything about them was engineered to perform. The processor module Dave found in his mailbag was worth $250,000 in 1991, and from the look of it was worth every penny. From the 64-layer ceramic substrate supporting up to 121 individual dies to the stout oil-filled aluminum enclosure, everything about this module is impressive. We were particularly intrigued by the spring-loaded copper pistons used to transfer heat away from each die; the 2,772 pins on the other side were pretty neat too.

Here’s an interesting question: what happens if an earthquake occurs in the middle of a 3D printing run? It’s probably not something you’ve given much thought, but it’s something that regular reader Marius Taciuc experienced recently. As he relates, the magnitude 6.7 quake that struck near Kainatu in Papua New Guinea (later adjusted to a 6.3 magnitude) resulted in a solid 15 seconds of shaking at his location, where he was printing a part on his modified Mendel/Prusa i2. The shaking showed up clearly in the part as the machine started swaying with the room. It’s probably not a practical way to make a seismograph, but it’s still an interesting artifact.

Heavy Metal Power Bank Uses Tool Batteries

At one time or another, most of us have seen a gadget for sale and thought we could build something similar for cheaper. Of course, we’re almost always wrong. Not about being able to build it, mind you. But when you add up the cost of the materials, the tool or two you almost inevitably end up buying, and the time spent chasing perfection, you’re lucky if you haven’t doubled the original price.

We’re not sure how much money [Taylor Hay] ended up saving by building his own portable power bank. But we do know it’s a gorgeous piece of hardware that’s certainly built far better than the average consumer gadget. The CNC-cut aluminum side panels look like something pulled out of a tank, and while we know some might balk at the 3D printed internal frame, we’re confident you could use this thing as an impromptu step stool without a problem.

Inside there’s 150 watt 240 VAC inverter, complete with a temperature-controlled fan to keep it cool under load. There are also four USB ports providing 2.1 A each, a standard 12 VDC accessory port, and a LED display that shows battery voltage and current being drawn. Rather than come up with his own battery pack, [Taylor] used a 3D printed interface that accepts an 18 V Milwaukee cordless tool battery. Naturally, the design could be adapted to take another brand’s cells if you were so inclined.

Around these parts, we know that a good project doesn’t have to be cheaper or even more practical than what’s already on the market. There’s an inherent value in building something exactly the way you want it that you simply can’t put a monetary price on.

Continue reading “Heavy Metal Power Bank Uses Tool Batteries”

Teaching An Old Lathe New Tricks With A Programmable Power Feed

Ask anybody whose spent time standing in front of a mill or lathe and they’ll tell you that some operations can get tedious. When you need to turn down a stainless rod by 1/4″ in 0.030″ increments, you get a lot of time to reflect on why you didn’t just buy the right size stock as you crank the wheel back and forth. That’s where the lead screw comes in — most lathes have a gear-driven lead screw that can be used to actuate the z-axis ( the one which travels parallel to the axis of rotation). It’s no CNC, but this type of gearing makes life easier and it’s been around for a long time.

[Tony Goacher] took this idea a few steps further when he created the Leadscrew Buddy. He coupled a beautiful 1949 Myford lathe with an Arduino, a stepper motor, and a handful of buttons to add some really useful capabilities to the antique machine. By decoupling the lead screw from the lathe’s gearbox and actuating it via a stepper motor, he achieved a much more granular variable feed speed.

If that’s not enough, [Tony] used a rotary encoder to display the cutting tool’s position on a home-built Digital Readout (DRO). The pièce de résistance is a “goto” command. Once [Tony] sets a home position, he can command the z-axis to travel to a set point at a given speed. Not only does this make turning easier, but it makes the process more repeatable and yields a smoother finish on the part.

These features may not seem so alien to those used to working with modern CNC lathes, but to the vast majority of us garage machinists, [Tony]’s implementation is an exciting look at how we can step up our turning game. It also fits nicely within the spectrum of lathe projects we’ve seen here at Hackaday- from the ultra low-tech to the ludicrously-precise.

Continue reading “Teaching An Old Lathe New Tricks With A Programmable Power Feed”

This DIY Drill Press Is Very Well Executed

Plenty of projects we see here could easily be purchased in some form or other. Robot arms, home automation, drones, and even some software can all be had with a quick internet search, to be sure. But there’s no fun in simply buying something when it can be built instead. The same goes for tools as well, and this homemade drill press from [ericinventor] shows that it’s not only possible to build your own tools rather than buy them, but often it’s cheaper as well.

This mini drill press has every feature we could think of needing in a tool like this. It uses off-the-shelf components including the motor and linear bearing carriage (which was actually salvaged from the Z-axis of a CNC machine). The chassis was built from stock aluminum and bolted together, making sure to keep everything square so that the drill press is as precise as possible. The movement is controlled from a set of 3D printed gears which are turned by hand.

The drill press is capable of drilling holes in most materials, including metal, and although small it would be great for precision work. [ericinventor] notes that it’s not necessary to use a separate motor, and that it’s possible to use this build with a Dremel tool if one is already available to you. Either way, it’s a handy tool to have around the shop, and with only a few modifications it might be usable as a mill as well.

Continue reading “This DIY Drill Press Is Very Well Executed”

Cyberplotter Uses Multiple Tools To Great Success

The CNC bug is a familiar ailment in these parts. Often, patients present with persistent obsession with computer controlled machinery, most commonly after initial contact with gateway hardware such as 3D printers or basic plotters. Once diagnosed, there is no cure – simply the desire to build, and build again. [Adam Haile] knows this all too well, and built the Cyberplotter in service to the affliction. 

The Cyberplotter is the culmination of [Adam]’s CNC wishlist – a two-axis build with a seriously large build area, and the capability to mount a whole bunch of different tools for different jobs. With a work area of up to 800mm x 750mm depending on what’s mounted, it can produce some seriously big output. With a Smoothieboard 5X running the show, [Adam] does all kinds of neat hacks to make the system play with different gadgets on the business end. There’s a laser for engraving, and a top-notch pen plotter featuring a high-quality linear rail for precise movement. But the fun doesn’t stop there – [Adam] goes so far as mounting a Z-axis, camera, and even a Sharpie-based airbrush which we’d never even contemplated before.

It’s not [Adam]’s first build, and past experience shines through here – armed with prior knowledge, the build does many things well without compromising on outright capability. You may find [Adam]’s name familiar – we’ve featured his Engravinator on these pages before. Video after the break.

Continue reading “Cyberplotter Uses Multiple Tools To Great Success”