foam

48 Articles

DIY Closed-Cell Silicone Foam

April 5, 2020 by 9 Comments

Most of us have a junk drawer, full of spare parts yanked from various places, but also likely stocked with materials we bought for a project but didn’t use completely. Half a gallon of wood glue, a pile of random, scattered resistors, or in [Ken]’s case, closed-cell silicone foam. Wanting to avoid this situation he set about trying to make his own silicone foam and had a great degree of success.

Commercial systems typically rely on a compressed gas of some sort to generate the foam. Ken also wanted to avoid this and kept his process simple by using basic (pun intended) chemistry to generate the bubbles. A mixture of vinegar and baking soda created the gas. After a healthy amount of trial and error using silicone caulk and some thinner to get the mixture correct, he was able to generate a small amount of silicone foam. While there only was a bit of foam, it was plenty for his needs. All without having a stockpile of extra foam or needing to buy any specialized equipment.

We appreciate this project for the ingenuity of taking something relatively simple (an acid-base reaction) and putting it to use in a way we’ve never seen before. While [Ken] doesn’t say directly on the project page what he uses the foam for, perhaps it or a similar type of foam could be used for building walk-along gliders.

Photo via Wikimedia Commons

Infinite Flying Glider

April 2, 2020 by 5 Comments

If you’ve exhausted your list of electronics projects over the past several weeks of trying to stay at home, it might be time to take a break from all of that and do something off the wall. [PeterSripol] shows us one option by building a few walkalong gliders and trying to get them to fly forever.

Walkalong gliders work by following a small glider, resembling a paper airplane but made from foam, with a large piece of cardboard. The cardboard generates an updraft which allows the glider to remain flying for as long as there’s space for it. [PeterSripol] and his friends try many other techniques to get these tiny gliders, weighing in at around half a gram, to stay aloft for as long as possible, including lighting several dozen tea candles to generate updrafts, using box fans, and other methods.

If you really need some electricity in your projects, the construction of the foam gliders shows a brief build of a hot wire cutting tool using some nichrome wire attached to a piece of wood, and how to assemble the gliders so they are as lightweight as possible. It’s a fun project that’s sure to be at least several hours worth of distraction, or even more if you have a slightly larger foam glider and some spare RC parts.

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CNC Hot-Wire Cutter Gives Form To Foam

February 1, 2020 by 12 Comments

Rapid prototyping tools are sometimes the difference between a project getting off the ground and one that stays strictly on paper. A lightweight, easy-to-form material is often all that’s needed to visualize a design and make a quick judgment on how to proceed. Polymeric foams excel in such applications, and a CNC hot-wire foam cutter is a tool that makes dealing with them quick and easy.

We’re used to seeing CNC machines where a lot of time and expense are put into making the frame as strong and rigid as possible. But [HowToMechatronics] knew that the polystyrene foam blocks he’d be using would easily yield to a hot nichrome wire, minimizing the cutting forces and the need for a stout frame. But the aluminum extrusions, 3D-printed connectors. and linear bearings he used still make for a frame stiff enough to give clean, accurate cuts. The addition of a turntable to the bed is a nice touch, turning the tool into a 2.5D machine. The video below details the construction and goes into depth on the toolchain [HowToMechatronics] used to go from design to G-code, including the tricks he used for making a continuous path, as well as integrating the turntable to make three-dimensional designs.

Plenty of hot-wire foam cutters have graced our pages before, everything from tiny hand-held cutters to a hot-wire “table saw” for foam. We like the effort put into this one, though, and the possibilities it opens up.

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Autonomous Boat For Awesome Video Hyperlapses

December 21, 2019 by 7 Comments

With the ever-increasing capabilities of smart phones, action cameras, and hand-held gimbals, the battle for the best shots is intensifying daily on platforms like YouTube and Instagram. Hyperlapse sequences are one of the popular weapons in the armoury, and [Daniel Riley] aka [rctestflight] realised that his autonomous boat could be an awesome hyperlapse platform.

This is the third version of his autonomous boat, with version 1 suffering from seaweed assaults and version 2 almost sleeping with the fishes. The new version is a flat bottomed craft was built almost completely from pink insulation foam, making it stable and unsinkable. It uses the same electronics and air boat propulsion as version 2, with addition of a GoPro mounted in smart phone gimbal to film the hyper lapses. It has a tendency to push the bow into the water at full throttle, due to the high mounted motors, but was corrected by adding a foam bulge beneath the bow, at the cost of some efficiency.

Getting the gimbal settings tuned to create hyperlapses without panning jumps turned out to be the most difficult part. On calm water the boat is stable enough to fool the IMU into believing that it’s is not turning, so the gimbal controller uses the motor encoders to keep position, which don’t allow it to absorb all the small heading corrections the boat is constantly making. Things improved after turning off the encoder integration, but it would still occasionally bump against the edges of the dead band inside which the gimbal does not turn with the boat. In the end [Daniel] settled for slowly panning the gimbal to the left, while plotting a path with carefully calculated left turns to keep the boat itself out of the shot. While not perfect, the sequences still beautifully captured the night time scenery of Lake Union, Seattle. Getting it to this level cost many hours of midnight testing, since [Daniel] was doing his best to avoid other boat traffic, and we believe it paid off.

We look forward to his next videos, including an update on his solar plane. Continue reading “Autonomous Boat For Awesome Video Hyperlapses” →

Building A Foam Machine From A Leaf Blower And A Water Pump

June 28, 2019 by 24 Comments

Imagine a tub overflowing with bubble bath, except it’s a club dancefloor and music is pumping all night. This is what is known as a “foam party” — a wild and exciting concept that nonetheless many are yet to experience. The concept exploded in popularity in Ibiza in the 1990s, and foam parties are regularly held at nightclubs and festivals the world over.

Foam is generated with the obviously-named foam machine, and these can be readily purchased or hired for anyone wishing to host such an event. However, that’s not the hacker way. If you’re a little ingenious and take heed of the safety precautions, here’s how you can do it yourself.

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Lifelike Dinosaur Emerges From The Plumbing Aisle

May 15, 2019 by 26 Comments

Despite the incredible advancements in special effects technology since the film’s release, the dinosaurs in 1993’s Jurassic Park still look just as terrifying today as they did nearly 30 years ago. This has largely been attributed to the fact that the filmmakers wisely decided to use physical models in many of the close-up shots, allowing them to capture the nuances of movement which really helps sell the idea you’re looking at living creatures.

[Esmée Kramer] puts that same principle to work in her incredible articulated dinosaur costume, and by the looks of it, Steven Spielberg could have saved some money if he had his special effects team get their supplies at the Home Depot. Built out of PVC pipes and sheets of foam, her skeletal raptor moves with an unnerving level of realism. In fact, we’re almost relieved to hear she doesn’t currently have plans on skinning the creature; some things are better left to the imagination.

In her write-up on LinkedIn (apparently that’s a thing), [Esmée] explains some of the construction tricks she used to help bring her dinosaur to life, such as heating the pipes and folding them to create rotatable joints. Everything is controlled by way of thin ropes, with all the articulation points of the head mirrored on the “steering wheel” in front of her.

Now to be fair, it takes more than a bundle of PVC pipes to create a convincing dinosaur. Obviously a large part of why this project works so well is the artistry that [Esmée] demonstrates at the controls of her creation. Judging by her performance in the video after the break, we’re going to assume she’s spent a not inconsiderable amount of time stomping around the neighborhood in this contraption to perfect her moves.

In the past we’ve seen the Raspberry Pi used to upgrade life-sized animatronic dinosaurs, but even with the added processing power, those dinos don’t hold a candle to the smooth and organic motion that [Esmée] has achieved here. Just goes to show that sometimes low-tech methods can outperform the latest technological wizardry.

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Making A Flying Wing With Expanding Foam

April 21, 2019 by 9 Comments

Many radio control aircraft modelers will be familiar with the process of cutting wings out of foam with the hot wire method. The tools are simple enough to build at home, and it’s an easy way of producing a lightweight set of wings without too much hassle. [IkyAlvin] walks a different path, however (YouTube link, embedded below).

Expanding foam is the key here – that wonderful sticky material in a can that never quite goes where you want it to. MDF and foam is used to create a mold to produce the wing forms. It’s then a simple matter of loading floor underlay into the mold to act as the outer skin, and then filling the mold with expanding foam and waiting for it to cure.

The final parts are assembled into a flying wing, and the first test flight is remarkably successful. Using foam overlay as a skin also has the added benefit of providing a sleek silver finish to the aircraft. It goes to show that there’s always room to explore alternative techniques outside of the mainstream. If you’d like to get more familiar with the classic hot wire technique, though, we can help there too. Video after the break.

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