Open Source Linear Bearing System

May 10, 2011 by Mike Nathan 53 Comments

makerslide

While we normally don’t make it a habit to feature Kickstarter projects, we couldn’t pass this one up. [Barton Dring] from BuildLog.net is putting together a project called MakerSlide that we’re sure will interest many of you out there.

Through his various CNC builds, he has found that one of the more expensive and frustrating components to obtain is a linear bearing system. He notes that commercial systems are expensive, and while an occasional eBay bargain can be found, it’s not the ideal way of going about things. He also points out that homebrew systems usually work after some tuning and adjustments, but can be time consuming to build.

He is proposing a v-groove bearing system, complete with wheels made from Delrin, as a standardized replacement for all of the aforementioned solutions. He anticipates selling the rails for about 10 cents per centimeter, putting the average cost of a 4 foot system around $20.

As a bonus, he is offering up free MakerSlide materials to anyone that sends him a “new, innovative or interesting open source design or basic idea that uses the material.” You would only have to pay shipping in order to get your new project off the ground.

Standardization is always good, and seeing this rail system go into production would definitely benefit the hacker community. Take a minute to check it out if you are so inclined.

A Weighted Companion Cube Worth Saving From The Incinerator

May 4, 2011 by Mike Nathan 19 Comments

companion_cube

It’s honestly sad that Valve has not released any official Portal-related items to the masses, as a market for them clearly exists. As the saying goes, “necessity is the mother of invention”, and [Jamie] needed a Weighted Companion Cube in the worst way.

Actually he constructed his Companion Cube in order to test out some modifications and upgrades he performed on his homebrew CNC Mill. Judging by how the cube turned out, and the fact that he was able to keep tolerances within .005”, we would say that his mill is working just fine.

The cube was designed in Solidworks, and passed through the BobCAD plugin to generate the GCode for the mill. The base of the cube was machined out of a 3” solid block of aluminum, hollowed out on one side to give him access to the cube’s innards. He milled out heart shaped openings on each side, covering them with frosted Lexan.

He added a BlinkM to the mix, mounting it on the cover plate he milled for the open side of the cube. Once lit it cycles through several colors, including the pinkish tone anyone who has played Portal is quite familiar with.

We would say that it’s a great job, but it doesn’t do his work justice – it’s absolutely stunning. We’re not just saying that because we want one, though we do want one…badly.

3D Printed Strandbeests Made To Order

May 2, 2011 by Mike Nathan 27 Comments

strandbeest

If you love Strandbeests but don’t have the patience to build your own, Dutch artist [Theo Jansen] has you covered. You might remember him from a story we ran last year, detailing his awesome beach-going strandbeest creations.

His beach walkers are typically built out of PVC conduit and plastic tubing, towering over their creator. For the time being however, he is focusing his work on a much smaller scale. [Theo] has recently teamed up with a 3D printing shop in order to offer miniature working replicas of his creations to the public. The current models can be had for $105, which seems like a pretty steep price to us. Then again, these models come fully assembled and are composed of 76 individual pieces, which is nothing to sneeze at.

That said, considering how easily a Strandbeest can be created with a stack of thick paper and some free time, we imagine that an enterprising individual could build one using readily available plastics at a fraction of the cost. Anyone out there up for giving it a shot?

Continue reading to see a video of the Strandbeest creation process.

[via Gizmodo]

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Save Boatloads Of Cash By Building Your Own Laser Cutter

April 14, 2011 by Mike Nathan 26 Comments

diy_laser_build

Have a bunch of time on your hands, and about $2,500 sitting around? Why not settle in and build yourself a laser cutter?

That’s exactly what Buildlog forum member [r691175002] did, and he told us about it in our comments just a few moments ago. Laser cutters can be pretty cost prohibitive depending on what you are thinking of picking up. The cheapest Epilog laser we could find costs $8,000, and you know what can happen when you try buying a cheap laser online.

Instead of going for a ready-made cutter, he purchased an open-source kit from Buildlog, documenting the highlights of the build process online. The build log walks through a good portion of the construction starting with the frame and motor mounts, continuing through wiring up the electronics as well as some of the finishing touches. If you happen to head over to take a look around, you will find that there are plenty of pictures from various stages of the construction process to keep you busy for awhile.

With everything said and done, [Ryan] is quite happy with his laser. After going through the build process, he offers up some useful construction advice, as well as tips on sourcing cheaper hardware. He estimates that if he built the laser today, he could probably cut the costs nearly in half.

There’s no doubt about it – a $1300 laser cutter sounds pretty darn good to us.

PC Case Using CNC Router And Home Building Products

March 22, 2011 by Mike Szczys 19 Comments

[Reinventing Science] needed a project that he could use to test out his skills on a new CNC routing machine he recently acquire. He settled on building a PC case using easily obtained materials. What he ended up with is the clean-looking case seen above that was machined from materials you can pick up at the home store.

The bulk of the case is made from extruded PVC which is designed to perform like solid wood trim. He picked up one piece of the ‘lumber’ and cut out the front, back, top, bottom, and drive bay bezel. We expected the joints between the horizontal and vertical pieces to either be butt joints, or rabbits. But [Reinventing Science] wanted a cleaner look and managed to mill mortise and tenon joints. These are strong joints that leave a very nice finished look. Since the material is designed as a lumber replacement it shouldn’t be too surprising to see drywall screws used as the fasteners.

In addition to joinery, some other CNC tricks were used. The sides of the case were cut from clear acrylic, with a decorative bead milled in the surface. There’s also fan ports cut in the top and vents on the bottom, as well as some engraving with the name of the project just above the optical drive. The wood-grain embossing makes for an interesting final look; we’d like to see how this takes a few careful coats of paint.

If you’re interested in the CNC hardware used, take a look at the unboxing post that shares a few details.

CNC Etch-a-Sketch Draws On Itself

March 14, 2011 by Mike Nathan 9 Comments

cnc_etchasketch

Having never been any good with an Etch-a-Sketch, [Ben] decided it was time to tame the children’s toy that had taunted him for so long. He received one in a gift exchange a few years back and hung onto it, recently digging it out again to fit it with some CNC components.

Using his RepRap, he printed a set of mounting plates and gears to drive the Etch-a-Sketch’s dials. He installed a pair of Airpax steppers to the gears and wired them up to an ATmega AT90 USB board he had sitting around. He installed RepRap firmware on the microcontroller, since it has a built-in gcode interpreter, making it easy for him to upload any gcode file to the Etch-a-Sketch for drawing.

You can see a quick demonstration of the device in action below. He converted a spiral image to gcode, then uploaded it to the Etch-a-Sketch – the machine does the rest. It draws pretty quickly as well – [Ben] even suggests that he could probably get it moving fast enough to melt the stylus!

It would be great to see the Etch-a-Sketch configured to support an online interface. That way he could allow people to upload images to the device, later showing off the artwork in a web gallery not unlike the LOL Shield Theatre we featured last week.

[via Make]

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CNC-built R2-D2 Brings Childhood Dreams To Life

March 8, 2011 by Mike Nathan 7 Comments

As a kid, [Wes] always dreamed of building a full-size, functional R2-D2 droid from Star Wars. While most youthful aspirations such as this fall to the wayside amid adult responsibilities and commitments, he did not allow his dreams to disappear along with his childhood.

He began his droid-building journey armed only with his dreams and some assistance from the friendly folks over at R2Builders. The entire replica was built using MDF, wood, and styrene sheeting, along with just one tool: a CNC machine. He walks you through the every step of the construction, stopping to give recommendations on CNC hardware, software, etc. along the way. He also provides Gcode files for each of the pieces he has constructed, which should be a huge help to anyone looking to build a R2-D2 clone of their own.

It looks like he is just getting around to fitting motors into the leg housings of his R2-D2 replica, but we can’t wait to see what it looks like once he has all of the electronics and other details finished.

If you are interested in more R2-D2 coverage, look no further than right here.