DIY CNC Sandblaster Writes Large

April 8, 2018 by Jenny List 12 Comments

CNC machinery, once a piece of workshop exotica, has become such a staple of projects within our sphere as to have become relatively unremarkable. A decent 3D printer can be had without mortgaging a small country, and the honor roll of CNC router builders is long and distinguished. But there is still plenty to surprise us in CNC, and [Fabien Chouteau]’s project shows us this with surprising simplicity. He’s eschewed a router or extruder, and instead fit an off-the-shelf CNC machine kit with a sandblaster.

If you are used to a sandblaster as a means for removing rust from pieces of your motor vehicle, then it’s fair to say that this one isn’t of that ilk. Instead, it’s used in the manner of an engraver, to sandblast a pattern or text onto a surface. This is something he shows us in the video below the break, with a piece of metal and a sheet of glass.The sandblaster itself features a 1.5-litre soda bottle and is driven by an airline.

On the electronic side, he replaced the controller that came with the kit with an STM32F469 discovery board and an Arduino CNC shield. He has a G-code controller from a previous project, to which he’s added a board with a touch screen to create a simple control interface.

This is by no means the only sandblaster we’ve featured, if your interests lie in that direction we can show you everything from the simple to the extreme.

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Super-Blue CNC Part Fixturing

March 29, 2018 by Brian McEvoy 20 Comments

Simple clamps are great if you need to keep the pressure on two parallel surfaces, but if you have an irregular plane, or you need to cut through it, clamps are not the correct tool. The folks at [NYC CNC] feature a video with a clever hack borrowing from other disciplines. Painters tape is applied to the top of a level mounting surface in the machine and then burnished. The same is done to the bottom of the workpiece. Superglue is drizzled between the tape layers and pressed together so now the stock is held firmly below the toolhead.

Some parts are machined in the video, which can be seen below, and the adhesion holds without any trouble. One of the examples they cut would be difficult to hold without damage or stopping the machine. The accepted wisdom is that superglue holds well to a slightly porous surface like tape, but it doesn’t like do as well with smooth surfaces like metal. Removing residue-free tape at the end of a cut is also cleaner and faster than glue any day.

If you have yet to cut your teeth, you can watch our very own Elliot Williams getting introduced to CNC machines or a portable machine even a child can use.

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Incremental Sheet Forming With A CNC Machine

March 14, 2018 by Al Williams 27 Comments

If you want to form a piece of sheet metal into a shape, you’ll probably think about using a die. That’s certainly a great way to do it, but it presupposes you can create or purchase the die, which may be a showstopper for small projects. [Dardy-7] has worked out how to use a lesser-used technique — incremental sheet forming — to get similar results with a CNC machine. The idea is to trace out the form on the sheet metal with a round blunt tool.

He got good results using an inexpensive dapping tool, although he’s seen other use heated titanium ball bearings. In addition, he’s worked out how to adapt existing tool paths, like the ones you might download from the Internet, to use with this technique. You can see a video of the workflow below.

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Touchless Shop Doors Over-Engineered To A Blissful Level

March 11, 2018 by Dan Maloney 13 Comments

When [John Saunders] wanted an automatic door for his shop, rather than settle for a commercial unit, he designed and built a proximity-sensing opener to ease his passing. Sounds simple, right?

Fortunately for us, there are no half-measures at Saunders Machine Works, thanks to the multiple Tormach workcells and the people who know how to use them. The video below treats us to quite a build as a result; the first part is heavy on machining the many parts for the opener, so skip ahead to 8:33 if you’re more interested in the control electronics and programming.

The opener uses time-of-flight distance sensors and an Arduino to detect someone approaching, with a pneumatic cylinder to part a plastic strip curtain. [John] admits to more than a little scope creep with this one, which is understandable when you’ve got easy access to the tools needed to create specialized parts at will.

In the end, though, it works well for everyone but [Judd], the shop dog, and it certainly looks like it was a fun build to boot. [John]’s enthusiasm for mixing machining and electronics is infectious; check out his automated bowl feeder for assembly line use.

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Casting Metal Parts And Silicone Molds From 3D Prints

February 25, 2018 by Lara Grant 35 Comments

The invention of the relatively affordable 3D printer for home use has helped bring methods used to produce parts for prototypes, samples, and even manufacturing, closer to designers. This tutorial on how to cast metal parts from 3D printed silicone molds is a perfect example of how useful a 3D printer can be when you are looking to make a custom and durable metal part at home.

After 3D printing a mold design using an Ultimaker 2 [Matt Borgatti] casts the mold using Smooth-On Mold Star 15 that can withstand heat up to 450 °F (232 °C), which he points out is ideal for the low-temp metal casting alloy tin-bismuth comprised of 58% Bismuth and 42% Tin with a melting point of 281 °F.

You may have heard of molds created from 3D printed parts before, but what makes this tutorial great is that the author, [Matt Borgatti], really sets you up to be successful. He offers up plenty of insights including mold-making techniques and terminology like why you would need a well and runners designed as part of your mold when casting with metal.

You can either reproduce his designs or use the tutorial to create your own which makes it a good start for beginners as well as another method to file away for people who already have experience 3D printing molds. This post is also really a twofer. Not only do you get detailed instructions for the method but [Matt Borgatti] uses his casted metal part for a flat-pack camera arm he designed to document projects with which you can also build using his files found on Thingiverse.

To create molds for precision parts and to learn more about using a 3D printer as a tool in the casting process, check out this method for creating higher resolution molds with a resin printer.

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Vintage Sewing Machine To Computerized Embroidery Machine

February 21, 2018 by Brian McEvoy 19 Comments

It is February of 2018. Do you remember what you were doing in December of 2012? If you’re [juppiter], you were starting your CNC Embroidery Machine which would not be completed for more than half of a decade. Results speak for themselves, but this may be the last time we see a first-generation Raspberry Pi without calling it retro.

The heart of the build is a vintage Borletti sewing machine, and if you like machinery porn, you’re going to enjoy the video after the break. The brains of the machine are an Arduino UNO filled with GRBL goodness and the Pi which is running CherryPy. For muscles, there are three Postep25 stepper drivers and corresponding NEMA 17 stepper motors.

The first two axes are for an X-Y table responsible for moving the fabric through the machine. The third axis is the flywheel. The rigidity of the fabric frame comes from its brass construction which may have been soldered at the kitchen table and supervised by a big orange cat. A rigid frame is the first ingredient in reliable results, but belt tension can’t be understated. His belt tensioning trick may not be new to you, but it was new to some of us. Italian translation may be necessary.

The skills brought together for this build were vast. There was structural soldering, part machining, a microcontroller, and motion control. The first time we heard from [juppiter] was December 2012, and it was the result of a Portable CNC Mill which likely had some influence on this creation. Between then, he also shared his quarter-gobbling arcade cabinet with us.

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AT-ST High Chair Elevates Lucky Jedi Youngling

February 14, 2018 by Tom Nardi 20 Comments

As a new parent, there’s lots you have to do. You have to buy a car seat, get the baby’s room ready, figure out daycare; all the boring but unavoidable minutiae of shepherding a tiny human. But for the more creative types, that list might include warming up the 3D printer or putting a fresh bit in the CNC, as there’s no better way to welcome a little one into the world than giving them some custom gear to get started with.

That’s certainly been the plan for [Matthew Regonini], who’s been showering his son with DIY playthings. He recently wrote in to tell us about his awesome AT-ST high chair build that manages to turn the drudgery of getting a baby to eat into an epic worthy of a John Williams score.

This isn’t the first time [Matthew] has turned dead trees into Imperial hardware. Last year we covered his fantastic AT-AT rocker which utilized the same construction techniques. The parts are cut out of plywood with his CNC, separated, cleaned up on a spindle sander, and finally assembled with wood glue and a few strategic fasteners. The depth and level of detail he’s able to achieve when the individual pieces are stacked up is exceptionally impressive. If builds like these don’t get you thinking about adding a CNC to your workshop, nothing will.

As with the AT-AT, the finish on the high chair is simply a healthy application of polyurethane. This keeps the wood from being porous (important as this build will be seeing its fair share of food and liquids) while retaining a natural look. Some might be tempted to paint it up in appropriate Imperial colors, but that might be a bit imposing considering its intended occupant.

Really, the only downside with this build is how quickly his son will outgrow it. The obvious solution to the problem is a constant supply of fresh babies to pilot it, but that’s one type of creation that we don’t generally detail here on Hackaday. If you have questions, ask your parents.

Incidentally, it’s starting to look like we’ve got a plywood arms-race going on. We’re excited to see somebody take it to the next level. A little scared, but mainly excited.

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