DIY CNC Touch Probe

June 9, 2011 by Mike Nathan 8 Comments

diy_cnc_touchprobe

[Dennis] recently invested some money in the Tormach Tooling System for his CNC’d Sieg SX3 mill in order to make his tool changes easier. While the kit allows him to easily account for height offsets while changing tools, he has no quick, reliable means of locating the spindle in relation to his workpiece. Tired of manually finding the edges of his workpiece for each axis, he built himself a DIY touch probe to automate the process.

The theory behind the probe’s operation is pretty simple. In the probe’s housing, three conductive rods are mounted perpendicular to the probe tip. Each rod rests between two metal balls forming a complete circuit. When the probe touches the edge of his milling material, the circuit is broken, sending a signal to his CNC control box.

The probe is comprised of several different parts, milled from either aluminum or black delrin. [Dennis] says that after everything was assembled, the runout on the probe was unacceptable, so he made a few tweaks, and now the runout has been reduced to about 0.00025” – well within acceptable tolerance limits for any work he will be doing.

Be sure to check out his site, as there are plenty more pictures of the probe’s construction, as well as additional video.

In the meantime, continue reading to see a quick video of the finished probe in action.

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Machine Precisely, Methodically Arranges Water Droplets

June 8, 2011 by Mike Nathan 31 Comments

While some projects we feature are meant to perform a useful function or make life easier, others such as this art installation by [Pe Lang] are far less functional, but amazing nonetheless.

Taking a cue from CNC-style machines, his creation is an experiment in falling objects and the properties of water. The machine methodically moves along a small 370 x 330 mm plate that is constructed out of a special omniphobic material. A syringe full of water travels along with the machine’s arm, depositing a single 3.3 mm wide drop of water on the board every few seconds as it moves along. Due to the surface tension of the water, each droplet forms a near perfect sphere on the plate without disturbing any of its neighbors.

Once the machine is finished, it leaves the matrix of water droplets to evaporate, after which the machine starts its careful process once again. It really is amazing, regardless of the fact that it doesn’t exactly “do anything”.

Be sure to check out the video below to see the exhibit in action.

[via Make]

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DIY Inkjet Printer Begs To Be Hacked

June 3, 2011 by Mike Nathan 17 Comments

diy_inkjet

[Nicholas C Lewis, Patrick Hannan, Jared Knutzen, and Joy Markham], students from the University of Washington, have recently taken the wraps off a project which they have been collaborating on, a DIY inkjet printer. The group set out to construct a low cost, open source inkjet printer for personal use that utilizes standard inkjet technology. Their working prototype, pictured above, satisfies all of those requirements, making it an ideal device for the at-home hobbyist.

The printer was constructed from easy to obtain components such as steel rods and stepper motors, along with other parts that can be printed using a RepRap or similar machine. An Arduino Mega manages the steppers and repurposed print head, recreating whatever Processing-generated image it has been given.

The printer is quite a hit so far, and people are already talking about adapting the design to print on spherical objects (think EggBot), to create direct etch resist PCBs, and more. We think it would make a great direct to garment printer with just a few small tweaks.

Check out the short video embedded below to see the printer in action.

[via Make]

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A Keygen For The Real World

May 31, 2011 by Mike Nathan 39 Comments

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[Nirav] found that he rarely printed anything useful with his RepRap, so to shake things up, he decided he needed to work on a project that didn’t involve printing yet more RepRap parts.

The goal of his project was to create working replicas of house keys by simply using the code imprinted at the factory. He purchased a handful of used lock sets from eBay, then carefully measured the keys with a ruler and calipers to get the blank dimensions just right. After that was done, he looked around online and was eventually able to create an OpenSCAD model using a chart of pin depth specifications he located. By changing the last line in the model’s code he can print any coded key. For keys lacking a code, he can manually measure the height of each bit and print replicas that way as well. Once printed, he says that they keys are strong enough to turn most locks he has come across, including deadbolts.

This is undoubtedly a neat project in its own right, though we would be interested to see if someone could get it paired with a program like SNEAKEY to generate bit measurements by sight alone.

Hackaday Links: Monday, May 30th

May 30, 2011 by Mike Nathan 5 Comments

Huge, fully functional NES game pad replica

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Students at Dutch TU Delft university recently built a huge replica of the original NES controller (Google Translation), which is fully functional and can be used to play games on a large display screen they also installed. How big is it, you ask? It’s about 6 meters wide – over 30 times the size of the original NES game pad and requires participants to jump on the buttons to play.

Convert any image to G-code

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Members of [Forskningsavdelningen], a Swedish hackerspace, are working on software that will allow users to vectorize bitmap images in order to convert them to G-code files for CNC milling. A good portion of the project is complete, but there is still a bit of work to do, so you won’t see it in action for a while. When it’s ready, we’ll be sure to let you know.

Convert your lame Dead Space plasma cutter into a bonafide laser weapon

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If you forked out big bucks for the special edition of Dead Space 2, you know how lame the included plasma cutter replica is. Check out this video, that shows you how to convert your LED toy to a dual laser, fire starting, laser pistol. The process is pretty simple, so what are you waiting for?

Synchronized, LED-lit juggling balls

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[Jonathan] wrote in to share a project he and some friends have just finished. He’s not sharing a ton of details at the moment, but he has put up a video showing off their wireless LED juggling balls. All we know is that they use bright RGB LEDS, Zigbees for communication, and that they are awesome. We can’t wait to hear more about them!

Water cooled PS3 Laptop

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[Pirate] recently unveiled his latest work, a water-cooled Playstation 3 laptop. It looks pretty sharp, and can undoubtedly rival some of Ben Heck’s work, even if it does have an external PSU. Obviously having a separate power component isn’t necessarily ideal, but when you are cramming all of that water cooling goodness into such a small package, something has to give!

Why Build A CNC Mill When You Can Have A Chess Robot Instead?

May 23, 2011 by Mike Szczys 9 Comments

[Patrick McCabe] enjoys the challenge of playing chess against the computer but he wasn’t satisfied with the flat experience of on-screen gaming. No problem, he just built his own gantry-style chess robot that he can play against. Don’t be confused, he still doesn’t have to touch the pieces, but instead uses the dedicated control board seen on the left of the image above. The robotic arm that is mounted on a gantry takes care of moves for both players.

It’s a pretty normal CNC build, using four stepper motors to slide the moving bits along precision rod. An Arduino Mega drives the system, with a PC doing the heavy lifting using a program called My Robot Lab.

We certainly like it that [Patrick] spent a little bit of time making the cabinet and visible parts look nice. Chess is a civilized game and unfinished parts would be out-of-place. We didn’t see it in his writeup, but the one feature we’re really hoping he has implemented is the ability to have the robot automatically reset the board at the beginning of a game.

As you might have guess, you’ll find embedded video after the break.

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PCB Milling With A Makerbot

May 21, 2011 by Caleb Kraft 15 Comments

[Keith] wanted to use his makerbot for some PCB milling, but he ran into a pretty big problem. The platform that his PCB would sit on was mounted with a layer of double sided foam tape and was not perfectly aligned to the head. Not only that, but it would tilt when pressure was applied. This made the result of the milling completely unacceptable. To remedy this, he made a new platform that is not only rigid, but he has made it so that there is the ability to adjust it for perfect alignment via adjustment screws in the 4 corners. At the beginning of each session, he can be absolutely sure that everything is aligned perfectly and his PCBs show a huge improvement. You can see a comparison of the two in the following picture.