Using FreeCAD To Replace OEM Parts

June 10, 2023 by Bryan Cockfield 46 Comments

As much as we might all like it if manufacturers supported their products indefinitely with software updates or replacement parts, this just isn’t feasible. Companies fail or get traded, technologies evolve, and there’s also an economic argument against creating parts for things that are extremely old or weren’t popular in the first place. So, for something like restoring an old car, you might have to resort to fabricating replacement parts for your build on your own. [MangoJelly] shows us how to build our own replacement parts in FreeCAD in this series of videos.

The build does assume that the original drawings or specifications for the part are still available, but with those in hand FreeCAD is capable of importing them and then the model scaling to match the original specs shown. This video goes about recreating a hinge on an old truck, so with the drawings in hand the part is essentially traced out using the software, eventually expanding it into all three dimensions using all of the tools available in FreeCAD. One of the keys to FreeCAD is the various workbenches available that all have their own sets of tools, and being able to navigate between them is key to a build like this.

FreeCAD itself is an excellent tool for anyone repairing old vehicles like this or those making 3D prints, designing floorplans for houses, or really anything you might need to model in a computer before bringing the idea into reality. It does have a steep learning curve (not unlike other CAD software) so it helps to have a video series like this if you’re only just getting started or looking to further hone your design skills, but the fact that it’s free and open-source make it extremely attractive compared to its competitors.

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SMA Connector Footprint Design For Open Source RF Projects

June 2, 2023 by Dave Rowntree 10 Comments

When you first start out in the PCB layout game and know just enough to be dangerous, you simply plop down a connector, run a trace or two, and call it a hack. As you learn more about the finer points of inconveniencing electrons, dipping toes into the waters of higher performance, little details like via size, count, ground plane cutouts, and all that jazz start to matter, and it’s very easy to get yourself in quite a pickle trying to decide what is needed to just exceed the specifications (or worse, how to make it ‘the best.’) Connector terminations are one of those things that get overlooked until the MHz become GHz. Luckily for us, [Rob Ruark] is on hand to give us a leg-up on how to get decent performance from edge-launch SMA connections for RF applications. These principles should also hold up for high-speed digital connections, so it’s not just an analog game.

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Remote-Controlled Hypercar Slices Through Air

May 23, 2023 by Bryan Cockfield 17 Comments

Almost all entry-level physics courses, and even some well into a degree program, will have the student make some assumptions in order to avoid some complex topics later on. Most commonly this is something to the effect of “ignore the effects of wind resistance” which can make an otherwise simple question in math several orders of magnitude more difficult. At some point, though, wind resistance can’t be ignored any more like when building this remote-controlled car designed for extremely high speeds.

[Indeterminate Design] has been working on this project for a while now, and it’s quite a bit beyond the design of most other RC cars we’ve seen before. The design took into account extreme aerodynamics to help the car generate not only the downforce needed to keep the tires in contact with the ground, but to keep the car stable in high-speed turns thanks to its custom 3D printed body. There is a suite of high-speed sensors on board as well which help control the vehicle including four-wheel independent torque vectoring, allowing for precise control of each wheel. During initial tests the car has demonstrated its ability to corner at 2.6 lateral G, a 250% increase in corning speed over the same car without the aid of aerodynamics.

We’ve linked the playlist to the entire build log above, but be sure to take a look at the video linked after the break which goes into detail about the car’s aerodynamic design specifically. [Indeterminate Design] notes that it’s still very early in the car’s development, but has already exceeded the original expectations for the build. There are also some scaled-up vehicles capable of transporting people which have gone to extremes in aerodynamic design to take a look at as well.

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Share Your Projects: Making Helpful PCBs

May 9, 2023 by Arya Voronova 38 Comments

When it comes to things that hackers build, PCBs are a sizeable portion of our creative output. It’s no wonder – PCB design is a powerful way to participate in the hardware world, making your ideas all that more tangible with help of a friendly PCB fab. It’s often even more lovely when the PCB has been designed for you, and all you have to do is press “send” – bonus points if you can make a few changes for your own liking!

A lot of the time, our projects are untrodden ground, however, and a new design needs to be born. We pick out connectors, work through mechanical dimensions, figure out a schematic and check it with others, get the layout done, and look at it a few more times before sending it out for production. For a basic PCB, that is enough – but of course, it’s no fun to stop at ‘basic’, when there’s so many things you can do at hardly any cost.

Let’s step back a bit – you’ve just designed a board, and it’s great! It has all the chips and the connectors you could need, and theoretically, it’s even supposed to work first try. Now, let’s be fair, there’s an undeniable tendency – the more PCBs you design, the better each next one turns out, and you learn to spend less time on each board too. As someone with over two hundred PCBs under her belt, I’d like to show you a bunch of shortcuts that make your PCB more helpful, to yourself and others.

There’s a few ways that you can share your PCB projects in a more powerful way – I’d like to point out a few low-hanging fruits, whether README.md files or markings on the PCB itself. I’ve been experimenting quite a bit with external and embedded documentation of PCBs, as well as PCB sharing methods, got some fun results, and I’d like to share my toolkit through a few punchy examples and simple tricks. I’d also like to hear about yours – let’s chat! Continue reading “Share Your Projects: Making Helpful PCBs” →

How To Model A Twisted Part In FreeCAD

May 6, 2023 by Donald Papp 84 Comments

Quick references are handy, but sometimes it’s nice to have a process demonstrated from beginning to end. In that spirit, [Darren Stone] created a video demonstrating how to model a twisted part in FreeCAD, showing the entire workflow of creating the part as a blend of surfaces and curves that get turned into a solid.

FreeCAD is organized using the concept of multiple “workbenches” which are each optimized for different tools and operations, and [Darren] walks through doing the same jobs in a few different ways.

This twisted bracket is a simple part that is nevertheless nontrivial from a CAD perspective, and that makes it a good candidate for showing off the different workbenches and tools.

The video below is also pretty good overall demonstration of what designing a part from a mechanical drawing looks like when done in FreeCAD. As for mechanical drawings themselves, we’ve seen FreeCAD can be used to make those, too.

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Hinges Live Inside 3D Prints

May 1, 2023 by Bryan Cockfield 5 Comments

Since desktop 3D printers have become more common, we’ve seen dramatic shifts in all kinds of areas such as rapid prototyping, antique restoration, mass production of consumer goods, or even household repairs that might not have been possible otherwise. There are a lot of unique manufacturing methods that can be explored in depth with a 3D printer as well, and [Slant 3D] demonstrates how one such method known as the living hinge can be created with this revolutionary new tool.

Living hinges, unlike a metal hinge you might pick up at a hardware store, are integrated into the design of the part and made of the same material. Typically found in plastic containers, they allow for flexibility while keeping parts count and cost low. The major downside is that they create stresses in the materials when used, so their lifespan is finite. But there are a number of ways to extend their life, albeit with a few trade-offs.

The first note is to make sure that you’re using the right kind of plastic, but after that’s taken care of [Slant 3D] builds a few flexible parts starting with longer circular-shaped living hinge which allows greater range of motion and distributes the forces across a wider area, at a cost of greater used space and increased complexity. A few other types of living hinges are shown to use less space in some areas, but make the hinges only suitable for use in other narrower applications.

One of the more interesting living hinges he demonstrates is one that’s more commonly seen in woodworking, known there as a kerf bend. By removing strips of material from a sheet, the entire sheet can be rotated around the cuts. In woodworking this is often done by subtracting material with a CNC machine or a laser cutter, but in 3D printing the voids can simply be designed into the part.

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The BSides: More Curious Uses Of Off-the-shelf Parts

April 24, 2023 by Sonya Vasquez 10 Comments

Off-the-shelf stock parts are the blocks from which we build mechanical projects. And while plenty of parts have dedicated uses, I enjoy reusing them in ways that challenge what they were originally meant for while respecting the constraints of their construction. Building off of my piece from last time, I’d like to add to your mechanical hacking palette with four more ways we can re-use some familiar off-the-shelf parts. Continue reading “The BSides: More Curious Uses Of Off-the-shelf Parts” →