Fail Of The Week: The Follies Of A Bootstrapped CNC Mill

August 15, 2013 by Mike Szczys 34 Comments

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Anyone who’s built their own CNC machine from scratch will tell you that it’s no walk in the park. Heck, even commercially available (but hobby priced) 3D printers are no picnic to get running reliably. This offering is the tale of how [Brian Amos] failed at building a CNC mill over and over again. But hey, that ‘over and over again’ part is what makes great hackers. He not only documented what didn’t work, but shows the hacks that he tried using to work through each scrape.

We think the most interesting bits are in his second post, but start with the first one (it’s a quick read) to get the background on the project. The real issues start with a common one: a bed that is severely unlevel compared to the cutting head’s axes. The solution is to use a sacrificial bed, milling it out to match the surface to the tool. This exposed the next issue which is a misaligned Z axis. Some give in the entire support structure means problems with slop and backlash. And there’s even a very creative spiral-cut coupler to help account for alignment issues between the lead screws and motors.

The nice thing about building a mill is that you can turn around a use it to mill more accurate replacement parts. Just keep telling yourself that as you toil away at a project that just won’t seem to work!

We’re already looking for next week’s fail post topic. Help keep the fun rolling by writing about your past failures and sending us a link to the story.

Fail Of The Week: Inaugural Edition

August 8, 2013 by Mike Szczys 115 Comments

We’re sure you’ve all been waiting on the edge of your seats to see whose project makes it as the first Hackaday Fail of the Week. Wait no longer, it’s [Mobile Will] with his woeful tale about monitoring AC current usage.

He had been working on a microcontroller actuated mains outlet project and wanted an accurate way to measure the AC current being used by the device connected to it. The ADE7753 energy metering IC was perfect for this so he designed the board above and ordered it up from OSH Park. After populating the components he hooked it up to his Arduino for a test run, and poof! Magic blue smoke arose from the board. As you’ve probably guessed — this also fried the Arduino, actually melting the plastic housing of the jumper wire that carried the rampant current. Thanks to the designers of the USB portion of his motherboard he didn’t lose the computer to as the current protection kicked in, requiring a reboot to reset it.

We can’t wait to hear the conversation in the comments. But as this is our first FotW post we’d like to remind you: [Mobile Will] already knows he screwed up, so no ripping on his skills or other non-productive dibble. Let’s keep this conversation productive, like what caused this? He still isn’t completely sure and that would be useful information for designing future iterations. Update: here’s the schematic and board artwork.

We’ve got a bit more to share in this post so keep reading after the break.

Continue reading “Fail Of The Week: Inaugural Edition” →

Have You Failed Hard Enough To Be On Hackaday?

August 5, 2013 by Mike Szczys 46 Comments

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There’s so much more to be discovered when your projects just don’t want to work. Grinding out the bugs, getting past roadblocks, and discovering gotchas is where real hacking know-how comes from. But most people aren’t motivated to document their failures. We want to change that.

We want to roll out a new weekly feature that showcases failure… well documented failure. But we need YOU to give up the goods. Write about your failed experience on your blog, post it to our project forums with [FAIL] in the title, or you can just write everything in an email and send it to us. Which ever way you choose, you’ll need to tip us off that you’d like to make it to the front page (come on, it’s not bragging since it didn’t even work!). If you already know of well documented project fails send in those links too even if they’re not your projects.

Make sure you include at least one descriptive image — snapshots, diagrams, schematics, screencaps, anything that tells the story is fair game. To show you what we’re after here’s a few of our favorite failed projects:

We’d like to point out that all of these projects are interesting ideas that show off missteps along the way. We will not be trashing on your skills as a hacker, but instead celebrating the lessons learned and hearlding the sharing of ideas from otherwise doomed projects.