jig

42 Articles

Custom Polyurethane Belts Made Easy

May 15, 2024 by 13 Comments

If you need to make polyurethane belts in custom lengths, it’s not too hard. You just need to take lengths of flexible polyurethane filament, heat the ends, and join them together. In practice, it’s difficult to get it right by hand. That’s why [JBVCreative] built a 3D printed jig to make it easy. 

The jig consists of two printed sliders that mount on a pair of steel rods. Each slider has a screw-down clamp on top. The clamps are used to hold down each end of the polyurethane filament to be joined. Once installed in the jig, the ends of the filament can be heated with a soldering iron or other element. and then gently pushed together. The steel rods simply enable the filament to be constrained linearly so the ends don’t shift during the joining process.

The jig doesn’t produce perfect belts. There’s still a small seam at the join that is larger than the filament’s base diameter. A second jig for trimming the belt to size could be helpful in this regard. Still, it’s a super useful technique for making custom belts. This could be super useful to anyone needing to restore old cassette decks or similar mechanical hardware.

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Modular Vacuum Table Custom-Fits The Parts

March 31, 2024 by 3 Comments

[enhydra] needed to modify a bunch of side inserts from some cheap ABS enclosures, and to save time and effort, he created a simple vacuum table with swappable inserts to precisely fit the parts. Suction is provided by a shop vacuum (plugged in near the bottom in the photo above) and it worked very well! Sealing and gaskets weren’t even required.

A vacuum table provides a way to hold workpieces flat and secure while a CNC machine does its thing, and because no clamps are involved, it can really speed up repetitive work. [enhydra]’s solution combines a vacuum table with a jig that ensures every rectangular piece is held exactly where the machine expects it to be, making the whole process of modifying multiple units significantly more efficient.

The whole thing — vacuum table and modular top — was straightforward to CNC cut out of what looks like particle board and worked as-is, no added gaskets or seals required, making this a very economical solution.

Vacuum tables can be pretty versatile and applied in more than one way, so keep that in mind the next time you’re wondering how best to approach a workshop problem. We’ve seen a well-engineered table used to speed up PCB milling, and we’ve also seen a DIY vacuum table combined with a heat gun and plastic plates from the dollar store make a bare-bones thermoforming rig.

Plasma Cutting And 3D Printing Team Up To Make Bending Thick Sheet Steel Easier

October 28, 2023 by 7 Comments

Metalworking has always been very much a “mixed method” art. Forging, welding, milling, grinding; anything to remove metal or push it around from one place to another is fair game when you’ve got to make something fast. Adding in fancy new tools like CNC plasma cutting and computer-aided drafting doesn’t change that much, although new methods often do call for a little improvisation.

Getting several methodologies to work and play well together is what [tonygoacher] learned all about while trying to fabricate some brackets for an electric trike for next year’s EMF Camp. The parts would have been perfect for fabrication in a press brake except for the 4 mm thickness of the plate steel, which was a little much for his smallish brake. To make the bending a little easier, [tony] made a partial-thickness groove across the plasma-cut blank, by using a reduced power setting on the cutter. This worked perfectly to guide the brake’s tooling, but [tony] ran into trouble with more complicated bends that would require grooves on both sides of the steel plate.

His solution was to 3D print a couple of sacrificial guide blocks to fit the bed of the press brake. Each guide had a ridge to match up with a guide groove, this allowed him to cut his partial grooves for both bends on the same side of the plate but still align it in the press brake. Yes, the blocks were destroyed in the process, but they only took a few minutes to print, so no big deal. And it’s true that the steel tore a little bit when the groove ended up on the outside radius of the bend, but that’s nothing a bead of weld can’t fix. Good enough for EMF is good enough, after all.

The brief video below shows the whole process, including [tony]’s interesting SCARA-like CNC plasma cutter, which we’re a little in love with now. This isn’t the first time we’ve seen 3D prints used as tools in metalworking, of course, but we picked up some great tips from this one. Continue reading “Plasma Cutting And 3D Printing Team Up To Make Bending Thick Sheet Steel Easier” →

Machining A Golf Ball To Make A Lovely Tactile Volume Knob

May 17, 2023 by 11 Comments

Golf balls are wonderfully tactile things. They have a semi-grippy covering, and they’re a beautiful size and weight that sits nicely in the hand. Sadly, most of them just get smacked away with big metal clubs. [Jeremy Cook] recognized their value as a human interface device, though, and set about turning one into a useful volume knob.

The trick here is in the machining. [Jeremy] used a 3D printed jig to hold a golf ball tightly in place so that it could be machined using a milling machine. With the bottom taken off and a carefully-designed 3D printed insert in the bottom, the golf ball is ready to be used as a knob for a volume control. As for the hardware side of things, [Jeremy] used an existing USB keypad, fitting the golf ball onto the encoder for volume and seek control in various programs.

The results sadly weren’t ideal. While the golf ball sits nicely upon the encoder, [Jeremy] found the device uncomfortable to use. Size may be an issue, but we also suspect the crowding of the surrounding buttons has a role to play. It forces the wrist into an uncomfortable curve to access the ball without hitting the surrounding controls. Without that, it may be greatly improved.

Files are available for those wishing to make their own. We don’t get a lot of golf ball builds here on Hackaday, but we’d love to see more. Hit up the tipsline if you’ve got ’em. Video after the break.

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Self-Propelled Chainsaw Reduces Injuries

December 25, 2022 by 30 Comments

[Advoko] is an expert at milling logs into various sizes of boards. He typically uses nothing but a chainsaw to enable him to mill on-site without needing to bring any large or expensive equipment. The only problem is that sometimes he gets a little carried away running his mill non-stop until he has enough lumber for whatever project he is building, which has led to some repetitive strain injuries. To enable him to continue to run his mill, he’s created this self-propelled chainsaw jig.

The creation of the self-propelled chainsaw was a little serendipitous. [Advoko] needed to mill a tree which had fallen on a slope, and he couldn’t move the large trunk before starting to mill. To avoid fatigue while pulling his chainsaw upwards, he devised a system of rubber belts that would help pull the weight of the chainsaw up the hill. Noticing that if the chainsaw could have been operated downhill, it would essentially pull itself along the cut, he set about building a carriage for the mill to hold the chainsaw in place while it semi-autonomously milled lumber for him.

The chainsaw jig isn’t fully autonomous; [Advoko] still needs to start and stop the chainsaw and set up the jig. It does have a number of safety features to prevent damage to the jig, the chainsaw, and himself too, and over a number of iterations of this device he has perfected it to the point where he can start it on a cut and then do other tasks such as move boards or set up other logs for cutting while it is running, saving him both time and reducing his risk of other repetitive strain injuries. If you don’t fully trust the automatic chainsaw jig, take a look at this one which requires a little more human effort but still significantly reduces the strain of milling a large log.

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Square Cuts On Aluminum Extrusion, No Mill Required

May 20, 2022 by 53 Comments

If you’re looking for the perfect excuse to buy that big, beautiful Bridgeport mill, we’ve got some bad news: it’s not going to be making perfectly square end cuts on aluminum extrusion. Sadly, it’s much more cost-effective to build this DIY squaring jig, and search for your tool justification elsewhere.

There’s no doubting the utility of aluminum extrusion in both prototyping and production builds, nor that the versatile structural members often add a bit of class to projects. But without square cuts, any frames built from them can be seriously out of whack, leading to misery and frustration down the road. [Midwest Cyberpunk]’s mill-less solution uses a cheap Harbor Freight router as a spindle for a carbide endmill, riding on a laser-cut acrylic baseplate fitted with wheels that ride in the V-groove of — you guessed it — aluminum extrusions. A fence and clamping system holds the extrusion firmly, and once trammed in, the jig quickly and easily squares extrusions that have been rough cut with a miter saw, angle grinder, or even a hacksaw. Check out the video below for a peek at the build details.

We love the simplicity and utility of this jig, but can see a couple of areas for improvement. Adding some quick-throw toggle clamps would be a nice touch, as would extending the MDF bed and fence a bit for longer cuts. But even as it is, this tool gets the job done, and doesn’t break the bank like a mill purchase might. Still, if your heart is set on a mill, who are we to stand in the way?

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Solder stencil vacuu assist jig

Stencil Vacuum-Assist Helps Avoid The Heartbreak Of Smeared Solder Paste

December 22, 2021 by 9 Comments

While using a stencil should make solder paste application onto PCBs a simple affair, there are a number of “gotchas” that make it more art than science. Luckily, there are tools you can build, like this 3D-printed vacuum-assist stencil jig, that take a little of the finesse out of the process.

For those who haven’t had the pleasure, solder paste stencils are often used to make the job of applying just the right amount of solder paste onto the pads of a PCB, and only on the pads. The problem is that once the solder paste has been squeegeed through the holes in the stencil, it’s not easy to remove the stencil without smearing. [Marius Heier]’s stencil box is essentially a chamber that attaches to a shop vac, along with a two-piece perforated work surface. The center part of the top platform is fixed, while the outer section moves up and down on 3D-printed springs.

In use, the PCB is placed on the center fixed platform, while the stencil sits atop it. Suction pulls the stencil firmly down onto the PCB and holds it there while the solder paste is applied. Releasing the suction causes the outer section of the platform to spring up vertically, resulting in nice, neat solder-covered pads. [Marius] demonstrates the box in the video below, and shows a number of adapters that would make it work with different sized PCBs.

If you think you’ve seen a manual vacuum stencil box around here recently, you’re right — we featured one by [UnexpectedMaker] not too long ago.

Continue reading “Stencil Vacuum-Assist Helps Avoid The Heartbreak Of Smeared Solder Paste” →