Building A Googie-Style Sign With The Help Of CNC

July 2, 2019 by Lewin Day 8 Comments

The Googie style was a major architectural trend of the post-war period in the United States. It remains popular to throwback to this style, and [Wesley Treat] got the job to create a sign in this vein for a local trailer motel (Youtube link, embedded below).

CNC tools make just about any job easier, and this one is no exception. The smooth curves of the sign were carved out of several sections of PVC sheet, and stacked up to form the body of the sign. These were then sanded, coated in putty, and given a lick of paint. Steps like these could likely be skipped in the interest of saving time, especially given that few will see those parts once the sign is installed. However, [Wesley] takes pride in his work, and the final piece is all the better for it. It’s also important for the piece to impress the client, not just the public.

The front of the sign is also produced in PVC sheet, and given a coat of paint with brush techniques used to create a faux-wood finish. Vinyl is then applied to the textual and graphical elements in order to create a colored backlit effect. The sign is lit with off-the-shelf LED strips, and the whole assembly is weather sealed to protect it from the elements.

The final product is a beautiful piece, harking back to the classic Googie aesthetic and serving as a testament to [Wesley]’s skills. It’s a great example of how easy it is to create great work with the right tools and the proper attention to detail. It also goes to show how great LEDs are for signage, whether you’re at the beach or the lab. Video after the break.

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Wire Bender Aims To Take Circuit Sculptures To The Next Level

July 1, 2019 by Dan Maloney 28 Comments

It doesn’t seem as though bending wire would be much of a chore, but when you’re making art from your circuits, it can be everything. Just the right angle in just the right place can make the difference between a circuit sculpture that draws gasps and one that’s only “Meh.”

[Jiří Praus] creates circuit sculptures that are about as far away from the “Meh” end of the spectrum as possible. And to help him make them even more spectacular, he has started prototyping a wire-bending machine to add precision to his bends. There’s no build log at the moment, but the video below shows progress to date. All the parts are 3D-printed, with two NEMA 17 steppers taking care of both wire feed and moving the bending head. It appears that the head has multiple slots for tools of different shapes. For now, the wire is rotated around its long axis manually, but another stepper could be added to take care of that job.

[Jiří] tells us that while he loves making circuit sculptures like his amazing mechanical tulip, he hates repeating himself. He hopes this bender will make repeat jobs a little less tedious and a lot more precise, and we hope he goes forward with the build so we get to see both it and more of his wonderful works of circuit art.

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FarmBot Unveils New CNC Gardening Robot Models

July 1, 2019 by Jenny List 16 Comments

Across the Northern Hemisphere it is now summer and the growing season is in full swing. Vigorous plants that will soon bear tasty fruit are springing forth from the soil, but unfortunately so are a lush carpet of weeds that require the constant attention of the gardener. “If only there were a machine that could take that on!” she cries, and as it happens she’s in luck.

The FarmBot is an open-source robotic vegetable grower able to take care of all aspects of sowing and tending a vegetable plot. We first saw them five years as a semifinalist in the first Hackaday Prize. This is a CNC machine for the raised beds of your backyard garden. Give it power, water, and a WiFi connection, and FarmBot goes into service planting, watering, weeding, and monitoring the soil. Now they’ve shipped over a thousand of their Genesis model and today have announced of a pair of new models that promise to make their technology more accessible than it ever has been.

FarmBot moisture sensor and watering head — FarmBot has a tool changer. Soil moisture sensor and watering heads are shown here.

In a nod to Tesla, FarmBot is calling this their “Model 3 moment” — the new offering is smaller and leaner to appeal to a wider customer base than their well-heeled, CNC machine loving, early adopters. The new FarmBot Express and Express XL models are now shipped 95% pre-assembled to lower the bar on getting up and running. They cover two sizes of planting bed: 1.2m x 3m or 2.4m x 6m, with an MSRP of $2295/2795 although there is currently an $800 launch discount available.

For us, FarmBot is the success story of an early Hackaday Prize entrant. From a great idea and a functional prototype, the project has successfully made the transition to commercial viability and holds a genuine promise of making the world a better place by helping people grow some of their own produce. Who knows, in five years time it could be your idea that’s reaching commercial viability, we think you should enter the Hackaday Prize too!

Hackaday Links: June 30, 2019

June 30, 2019 by Brian Benchoff 31 Comments

In our continuing series of, ‘point and laugh at this guy’, I present a Kickstarter for the, “World’s First Patented Unhackable Computer Ever”. It’s also a real web site and there’s even a patent (US 10,061,923, not showing up on Google Patents for some reason), and a real product: you can get an unhackable laptop, and you can get it in either space gray or gold finish. This gets fun when you actually dig into the patent; it appears this guy invented protected memory, with one section of memory dedicated to the OS, and another dedicated to the browser. This is a valid, live patent, by the way.

The 2019 New York Maker Faire is off. Yeah, it says it’s still going to happen on the website, but trust me, it’s off, and you can call the New York Hall of Science to confirm that for yourself. Maker Media died recently, and there will be no more ‘Flagship’ Maker Faires. That doesn’t mean the ‘mini’ and ‘featured’ Maker Faires are dead, though: the ‘Maker Faire’ trademark is simply licensed out to those organizers. In the next few weeks, there is going to be a (mini) Maker Faire in Coeur d’Alene, Idaho, Gilroy, California, Edmonton, Alberta, Kingsport Tennessee, and a big ‘ol one in Detroit. This raises an interesting question: where is the money for the licensing going? I’m sure some Mini Maker Faire organizers are reading this; have your checks been cashed? What is the communication with Maker Media like?

Just because you can, doesn’t mean you should. It’s valuable words of wisdom like that and can apply to many things. Commenting on blog posts, for example. Yes, you can throw sticks at a wasp’s nest, that doesn’t mean you should. Yes, you can 3D print Heely adapters for your shoes, but it doesn’t mean you should. It does look dope, though and you’re automatically a thousand times cooler than everyone else.

The C64 Mini is a pocket-sized Linux device with an HDMI port meant to play C64 games. There were high hopes when the C64 Mini was announced, but it turned out the keyboard isn’t actually a mini keyboard. Now someone had the good sense to combine one of these ‘smartphone chips running an emulator in a retro case’ products with a full-sized keyboard. The C64 will be around by Christmas, and yeah, it has a full working keyboard.

Custom Machined Pump Keeps CNC Lubrication Under Control

June 27, 2019 by Dan Maloney 19 Comments

Rub two pieces of metal against each other hard enough, and it won’t be long before they heat up sufficiently to cause problems. That’s especially true when one is a workpiece and one is a tool edge, and the problems that arise from failing to manage the heat produced by friction can cost you dearly.

The traditional way of dealing with this is by pumping heavy streams of liquid coolant at the workpiece, but while that works, it creates problems of its own. That’s where minimum quantity lubrication comes in. MQL uses a fine mist of lubricant atomized in a stream of compressed air, which saves on lube and keeps swarf cleaner for easier recycling. The gear needed for MQL can be pricey though, so [brockard] decided to add homebrew MQL to his CNC router, with great results.

The video below shows the whole process, from raw metal to finished system – skip ahead to about 12 minutes if you just want to see final testing, but be warned that you’ll be missing some high-quality machining. The finished pump is a double-piston design, with each side driven by a cam rotated by a servo. An Arduino controls the speed of the motor based on the current settings; the pump is turned on and off through G-code control of a relay.

The lubricant stream is barely visible in the video, as opposed to the sloshing mess of traditional flood coolants, and seems much more suitable for a hobbyist-grade CNC setup. Need to build a CNC router before you build this? You can do much worse than this one.

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Does The Cheese Grater Do A Great Grate Of Cheese?

June 24, 2019 by Jenny List 16 Comments

Apple’s newest Mac Pro with its distinctive machined grille continues to excite interest, but until now there has been one question on the lips of nobody. It’s acquired the moniker “Cheese grater”, but can it grate cheese? [Winston Moy] set out to test its effectiveness in the kitchen with a piece of Pecorino Romano, a great cheese.

Of course, the video is not really about cheese grating, but about the machining process to create that distinctive pattern of intersecting spherical holes. He doesn’t have a real Mac Pro because nobody does as yet, so like others his approach was to reverse engineer the manufacturing process. He takes us through the entire thing and the rationale behind his decisions as he makes a 13-hole piece of Mac Pro-like grill from a billet of aluminium. It’s first roughly cut with a pair of decreasing-size end mills, then finished with a ball mill. He’s added an extra cut to round off the sharp edge of the hole that isn’t there on the Mac.

An unexpected problem came when he machined the bottom and the holes began to intersect, it was clear that they were doing so wrongly. Turning the piece over must be done in the correct orientation, one to note for any other would-be cheese-grater manufacturers. Finally the piece is blasted for a satin finish, and then anodised for scratch-resistance.

So, the important question must be answered: does it grate? The answer’s no, the best it can manage is something close to a crumble. He doesn’t seem bothered though, we get the impression he likes eating cheese whatever its form. The whole process is in the video below the break.

For more Apple grille examination, take a look at this mathematical analysis.

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The Process Behind Manufacturing That Mac Pro Grille

June 19, 2019 by Jenny List 54 Comments

Apple released a monitor stand not so long ago with an eye-watering price tag, and in the resulting fuss you might almost be forgiven for missing the news that they also released a new computer. The distinctive grille on the new Mac Pro caused some interest among Hackaday editors, with speculation rife as to how it had been machined. It seems we’re not alone in this, because [J. Peterson] sent us a link to his own detailed analysis.

The key to the pattern lies in hemispherical holes milled part-way-through a piece of metal on a triangular tessellation, and intersecting with an identical set of holes milled at an offset from the other side. The analysis was done purely from online information as he doesn’t have a real Mac Pro, but using some clever trigonometry he is able to calculate the required offset as well as the hole depth. There are some STL files on Thingiverse, for the curious.

Should you wish to make your own copy of a Mac Pro grille you should therefore be able to use this information in programming a CNC mill to carve it from a piece of alloy plate. The interesting side of it from a manufacturing perspective though is that this is a complex shape that would be difficult to produce in numbers without either CNC or a very specialist one-off machine tool for this single purpose, and neither is a normal expenditure for a mere grille. Perhaps you might come close by rolling alloy plate between rollers whose profile matched the hole pattern, but in that event you would not equal the finish that they have achieved. Apple’s choice to use a relatively time-intensive CNC process in mass-production of a cosmetic part is probably in a large part a quality statement for their particular brand of consumer, but also sets a high bar to any would-be imitators. We applaud it for its engineering, even if we won’t be shelling out for that monitor stand.