CNC Milling Is More Manual Than You Think

November 27, 2017 by Elliot Williams 43 Comments

I was in Pasadena CA for the Hackaday Superconference, and got to spend some quality time at the Supplyframe Design Lab. Resident Engineer Dan Hienzsch said I could have a few hours, and asked me what I wanted to make. The constraints were that it had to be small enough to fit into checked luggage, but had to be cool enough to warrant taking up Dan’s time, with bonus points for me learning some new skills. I have a decent wood shop at home, and while my 3D printer farm isn’t as pro as the Design Lab’s, I know the ropes. This left one obvious choice: something Jolly Wrencher on the industrial Tormach three-axis CNC metal mill.

A CNC mill is an awesome tool, but it’s not an omniscient metal-eating robot that you can just hand a design file to. If you thought that having a CNC mill would turn you into a no-experience-needed metal-cutting monster, you’d be sorely mistaken.

Of course the machine is able to cut arbitrary shapes with a precision that would be extremely demanding if done by hand, but the craft of the operator is no less a factor than with a manual mill in making sure that things don’t go sideways. Dan’s good judgment, experience, and input was needed every step of the way. Honestly, I was surprised by how similar the whole procedure was to manual milling. So if you want to know what it’s like to sit on the shoulder of a serious CNC mill operator, read on!

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DIY Injection Mold Design For The Home Shop

November 11, 2017 by Dan Maloney 30 Comments

3D printing is great for prototyping, and not bad for limited runs of parts. Unfortunately though it really doesn’t scale well beyond a few pieces, so when you’re ready for the mass market you will need to think about injection molding your parts. But something like that has to be farmed out, right? Maybe not, if you know a thing or two about designing your own injection molds.

The video below comes from [Dave Hakkens] by way of his Precious Plastic project, whose mission it is to put the means of plastic recycling into the hands of individuals, rather than relying on municipal programs. We’ve covered their work before, and it looks like they’ve come quite a way to realizing that dream. This tutorial by [Dave]’s colleague [Jerry] covers the basic elements of injection mold design, starting with 3D modeling in Solidworks. [Jerry] points out the limitations of a DIY injection molding effort, including how the thickness of parts relates to injection pressure. Also important are features like gentle curves to reduce machining effort, leaving proper draft angles on sprues, and designing the part to ease release from the mold. [Jerry] and [Dave] farmed out the machining of this mold, but there’s no reason a fairly complex mold couldn’t be produced by the home gamer.

When you’re done learning about mold design, you’ll be itching to build your own injection mold machine. Precious Plastic’s tutorial looks dead simple, but this machine looks a little more capable. And why CNC your molds when you can just 3D print them?

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Homebuilt Laser Engraver Using Salvaged Parts

October 31, 2017 by Tom Nardi 25 Comments

Now that anyone can go online and get a fairly decent 3D printer for around $200, they’ve officially fallen out of the “Elite Hacker” arsenal and are now normal, if perhaps highly specialized, tools. That’s great for the 3D printing community as a whole, but what about those who want to be on the fringe of technology? Telling people you have a 3D printer at home doesn’t get that wide-eyed response like it used to. What’s a “l33t” hacker to do?

Enter the laser engraver/cutter: it’s like a 3D printer, but easier to build and has a higher capacity for bodily harm! While there are a couple good options for kits and turn-key setups out there, just like the early days of 3D printers, some of the best machines are still home built. In his latest video, YouTuber [MakerMan] takes us through his build which features an impressively low part count.

To start his build, [MakerMan] strips down four printers and salvages seven high quality 8 mm linear rods; a huge cost saving tip in itself. We’ll certainly be picking up any printers we see in the trash for the next couple months hoping to score some rods. With the addition of some cheap LM8UU bearings and 3D printed holders for them, [MakerMan] has a smooth 2D motion platform for just a couple bucks. The frame of the machine is built out of type of aluminum square tubing you can find at the hardware store, no expensive extrusion here.

For the laser itself, [MakerMan] is using a six watt PLH3D-6W-XF from Opt Lasers. This module features integrated driver and cooling, so all you need to do is provide it power and a stable means of moving it over the work piece. They even offer a magnetic “dock” which allows you to remove the laser from the mount without any tools for servicing or tool changes. [MakerMan] reports he’s been able to engrave stainless steel with this laser module, and cut thin wood.

This isn’t the first laser engraver we’ve seen built out of scrap parts, though if you want to save some work you could just upgrade a cheap commercial model.

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Imperial Rocker For Stopping Tiny Rebel Scum

October 25, 2017 by Tom Nardi 15 Comments

Some of the luckiest kids in the world have to be the ones with hackers and makers as parents. While normal kids are stuck playing with cookie cutter mass produced toys, these kids get one-off gadgets and creations that will be the envy of the playground. Frankly, some of the stuff ends up being so cool that it’ll get the adults wishing they could go back in time and play with it.

One such parent, and one such project, is the Imperial Rocker by [Matthew Regonini]. Hoping to instill an obsession with a galaxy far, far, away on his offspring, [Matthew] designed this AT-AT rocking horse piece by piece in Illustrator, and then cut it all out of birch using his XCarve CNC router. Each piece was then meticulously glued together to produce a final 3D effect from the individual cutouts.

With a liberal application of spring clamps to hold it all together while it dried, all that was left to do was painstakingly sand all the parts so the edges of the laminated construction would be smooth. Dowels were then added for the handlebars and foot pegs, and a few coats of polyurethane seal up the plywood while bringing out a natural look.

[Matthew] notes some issues here and there, notably quite a bit of blowout in some of the detail cuts and a couple miscalculated dimensions. But he reasons that the rocker is going to live a pretty hard life anyway, so best not to sweat the small stuff.

While the Imperial Rocker has that quaint old-school charm, we wonder how long it will be before [Matthew’s] little Stormtrooper starts yearning for the blinking lights and buttons that youngsters just can’t get enough of.

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Scratch Built Watch Case Is A Work Of Art

October 19, 2017 by Tom Nardi 33 Comments

The wristwatch was once an absolute necessity, as much fashion statement as it was a practical piece of equipment. Phones in our pockets (and more often than not, in our faces) replaced the necessity of the wristwatch for the majority of people, and the fashion half of the equation really only interests a relatively small subset of the population. The end result is that, aside from the recent emergence of smartwatches and fitness trackers, walking down the street it’s fairly unlikely you’ll see many people wearing a traditional watch.

But we think the scratch built wristwatch case recently shown off by [Colin Merkel] adds a new justification for wearing a watch: pride. From a chunk of steel rod stock, [Colin] walks through every step of the process to creating a professional looking watch case. This is actually his second attempt at the project; while his first one certainly didn’t look bad, he felt that he learned enough from his earlier mistakes that it was worth starting over from scratch. A man after our own heart, to be sure. Continue reading “Scratch Built Watch Case Is A Work Of Art” →

CNC Robot Makes A Move

October 12, 2017 by DJ Harrigan 30 Comments

Another day, another Kickstarter. While we aren’t often keen on touting products, we are keen on seeing robotics and unusual mechanisms put to use. The Goliath CNC has long since surpassed its $90,000 goal in an effort to put routing robots in workshops everywhere.

Due to their cost and complexity, you often only find omni-wheels on robots scurrying around universities or the benches of robotics hobbyists, but the Goliath makes use of nine wheels configured as three sets in a triangular pattern. This is important as any CNC needs to make compound paths, and for wheeled robots an omni-wheel base is often the best bet for compound 2D translation.

What really caught our eye is the Goliath’s unique positioning system. While most CNC machines have the luxury of end-stops or servomotors capable of precise positional control, the Goliath has two “base sensors” that are tethered to the top of the machine and mounted to the edge of the workpiece. Each sensor connects to the host computer via USB and uses vaguely termed “Radio Frequency technology” that provides a 100Hz update for the machine’s coordinate system. This setup is sure to beat out dead-reckoning for positional awareness, but details are scant on how it precisely operates. We’d love to know more if you’ve used a similar setup for local positioning as this is still a daunting task for indoor robots.

A re-skinned DeWalt 611 router makes for the core of the robot, which is a common option for many a desktop milling machine and other bizarre, mobile CNCs like the Shaper Origin. While we’re certain that traditional computer controlled routers and proper machining centers are here to stay, we certainly wouldn’t mind if the future of digital manufacturing had a few more compact options like these.

Engineering And Artistry Meet An Untimely End At Burning Man

October 6, 2017 by Dan Maloney 38 Comments

Burning Man is so many different things to so many people, that it defies neat description. For those who attend, it always seems to be a life-changing experience, for good or for ill. The story of one man’s Burning Man exhibition is a lesson in true craftsmanship and mind-boggling engineering, as well as how some events can bring out the worst in people.

For [Malcolm Tibbets], aka [the tahoeturner], Burning Man 2017 was a new experience. Having visited last year’s desert saturnalia to see his son [Andy]’s exhibition, the studio artist decided to undertake a massive display in his medium of choice — segmented woodturning. Not content to display a bamboo Death Star, [Malcolm] went big– really big. He cut and glued 31,000 pieces of redwood into rings of various shapes and sizes and built sculptures of amazing complexity, including endless tubes that knot and loop around and back into each other. Many of the sculpture were suspended from a huge steel tripod fabricated by [Andy], forming an interactive mobile and kinetic sculpture.

Alas, Burning Man isn’t all mellowness in the desert. People tried to climb the tripod, and overnight someone destroyed some of the bigger elements of the installation. [Malcolm] made a follow-up video about the vandalism, but you’ll want to watch the build video below first to truly appreciate the scale of the piece and the loss. Here’s hoping that [Malcolm]’s next display is treated with a little more respect, like this interactive oasis from BM 2016 apparently was.