Stirring Plate From USB Enclosure

March 25, 2011 by Mike Szczys 18 Comments

[Loreno Minati] built his own stir plate out of a hard drive enclosure. It’s the exact same hack as the one we saw a few weeks ago. A magnet was glued to the center of a computer fan, which causes the magnetic capsule inside the beaker to spin. This creates a vortex, evenly mixing the liquid.

Using a hard drive enclosure is a brilliant idea. It’s designed to sit in plain sight so you get a very nice finished look. It’s also exactly the right size for the fan itself. A potentiometer mounted in the cap of the enclosure allows for variable speeds, and the DC barrel jack is being used for the power source. Now that we think of it, this may be the best use of an external HDD enclosure we’ve ever seen (even eclipsing its original purpose). Check out a video and image gallery of the project after the break.

We’ve categorized this as a beer hack since stir plates are often built by hobbyists for growing yeast starters used in home brewing.

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Copper-clad Enclosures

December 8, 2010 by Mike Szczys 29 Comments

Building a great looking box for your projects can be a challenge. [Ken] boils down his process of building enclosures out of copper clad (PDF) circuit board material into an illustrated guide in case you want to try this for yourself. Why would you want to use PC board? The fiberglass substrate makes for a strong and lightweight material. Also, [Ken] is a ham radio operator and the copper coating acts as an electrical shield for delicate components inside.

As you can see above he uses solder to tack the pieces together. There’s some important considerations that go along with this method. First, he cuts the pieces just a bit oversized and then sands them flat and square before assembly. Next, he uses some 20 gauge wire as a shim between a ninety-degree joint and a right angle jig. This shim compensates for the shrinking that occurs as the solder cools, making sure the joint gets pulled to a right angle. He even solders nuts in place so that screws can be used to attach the case cover to the chassis.

Yesterday we saw toner transfer used to make labels on an ABS case. If you make your enclosure out of copper clad, using toner transfer for panel labels will be a snap!

Project Enclosures The Right Way

November 7, 2010 by Mike Szczys 11 Comments

[Stephen Eaton] created an enclosure and shared his process in a pair of blog post. We thought is was amusing that he remarks on how rarely his projects get the to point that you’d want to make an enclosure for them. We’ve certainly got a lot of bare-PCB creations lying around. But when it does come time, we think his fabrication method is a good way to go.

First of all, he didn’t start from scratch. He already had a SparkFun project case sitting around. The problem is figuring how to make it work for your situation. We’ve used a drill, a Dremel, and a file in the past and that yields passable results but nothing that would be mistaken for anything other than a carefully mangled project box. [Stephen] decided to mill the openings he needed from the box, which yielded professional looking results. He started by emailing SparkFun and asking if they could give him a 3D model of the project box and the obliged. He then modeled the LCD screen, LED light pipes, button, USB port, and SD socket. From there it was off to the mill with a custom jig and a few tricks we think you’ll appreciate. The end result is just another reason to build the CNC mill you’ve had on your mind for so long.

Server Enclosure From 22 Rolls Of Tape

July 9, 2010 by Mike Szczys 32 Comments

Who needs metal, wood, or acrylic if you are talented with duct tape? This server is housed in a 20-sided enclosure made entirely of duct tape, 22 rolls of it. A team of seven completed the project after eight build session over the course of about ten days. It’s currently in use at this year’s MillionManLan 9 as confirmed by this incredibly boring live feed.

However whimsical, we do appreciate the build process. Tubes are rolled until they reach the specified thickness, then cut to length on a chop saw. More sticky stuff is applied to the joints and piece by piece the frame comes together. From the diagram laying off to the side in one of the pictures it looks like they did the smart thing by designing this in CAD before getting their hands dirty sticky.

On-the-go Prototyping

April 6, 2010 by Mike Szczys 10 Comments

[Riley Porter] has been working on several different custom enclosure designs. Above, you can see his Proto Desk which holds a breadboard, Arduino, and has two recessed boxes with sliding tops for components and patch wires. He’s got a miniature version that gets rid of the breadboard, as well as slick-looking cases for the Bus Pirate, tinyISP, and face plates for word clocks.

Well, if you’ve got a laser cutter you should be using it right? We’ve seen [Riley’s] wares in the past; he wrote the guide for laser cutting solder stencils.

[Thanks Brian]

Transparent Rubber Enclosures

February 12, 2010 by Mike Szczys 31 Comments

This clear rubber puck serves as the enclosure for a diy mp3 player. The wires encapsulated in the rubber are just there for looks but the utility of using this material as a case is fascinating. Alas, there’s no details on the material other than that it’s clear rubber. Update: [Reboots] picked up on some info that we originally missed. Looks like this is made from some Smooth-On PCM 780 urethane rubber.

We’ve looked into casting our own molds from silicone rubber in the past. That may be the process used here but we can’t tell what allows the two halves to be pried apart. We’ve embedded video after the break that details casting rubber around a part in one solid block, then cutting the rubber off of that to create a mold. We’re also familiar with the mold making kits from Tap plastics but as far as we know, they’re always colored and never clear.

We keep our eyes peeled for new prototyping products and we want to know more about the materials and the process used to make this cylindrical elastomer. If you’ve got the goods on how this is done, please share them in the comments.

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Altoids Upstaged By Gift Card Tins

February 7, 2010 by Phil Burgess 27 Comments

Nothing Earth-shattering here. Just, dare we say it, really cute!

The venerable Altoids mint tin has become an icon of the maker culture. Browsing through past articles on Hack a Day, Adafruit or Instructables, you’ll find project after project for which these pocket-sized enclosures provided just the right fit. Eminently practical, affordable, but the aesthetics have occasionally left something to be desired.

We recently stumbled upon these nifty gift card holders that resemble miniature versions of current-generation game consoles. They might be the perfect housing for your next microcontroller project…

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