Curved Wood LED Lamp Needs No Fancy Tools

Those of us who aren’t familiar with woodworking might not expect that this curved wood and acrylic LED lamp by [Marija] isn’t the product of fancy carving, just some thoughtful design and assembly work. The base is a few inches of concrete in a plastic bowl, then sanded and given a clear coat. The wood is four layers of beech hardwood cut on an inverted jigsaw with the middle two layers having an extra recess for two LED strips. After the rough-cut layers were glued together, the imperfections were rasped and sanded out. Since the layers of wood give a consistent width to the recess for the LEDs, it was easy to cut a long strip of acrylic that would match. Saw cutting acrylic can be dicey because it can crack or melt, but a table saw with a crosscut blade did the trick. Forming the acrylic to match the curves of the wood was a matter of gentle heating and easing the softened acrylic into place bit by bit.

Giving the clear acrylic a frosted finish was done with a few coats of satin finish clear coat from a spray can, which is a technique we haven’t really seen before. Handy, because it provides a smooth and unbroken coating along the entire length of the acrylic. This worked well and is a clever idea, but [Marija] could still see the LEDs and wires inside the lamp, so she covered them with some white tape. A video of the entire process is embedded below.

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Hackit: Laser Cut Your Own Jigsaw Puzzle

If you have a laser printer, you’ve got your Christmas presents sorted out. At least if your family likes jigsaw puzzles. The idea is very simple, laminate a photograph onto some laser-cuttable board, and then run the laser over the outline of the pieces. Bam! Instant puzzle.

The trick is generating the puzzle outline, and of course there’s an online application for that. It’s got options that let you customize the piece count and shapes, and then download the result as an SVG image.

Unfortunately, it’s closed-source and makes the pieces a little bit too uniform for our liking — many of the pieces have exactly the same shape as each other. Are you up to the challenge of writing a better one? We’d love to see it, because the idea of a simple puzzle overlay for laser cutters is too good. Help us get started with some brainstorming in the comments below. How do you go about generating meaningfully unique jigsaw edges algorithmically?

Once you’ve got the puzzle cut out, you can seal up the surface nicely, toss it in a box, and then you’ve got a personalized present. To put it together, we suggest an accompanying DIY pick-and-place tool. (And kudos to [Kristina] for the best headline of 2015 on that one!)

Thanks to Hackaday alum [George Graves] for the tip!

Giant Spirograph Delights Children, Dwarfs Banana

giant spirographLate last year at a craft show, [hahabird] and a friend came across a laser-cut Spirograph and they both had a go at it. After mocking his friend’s lack of fine motor skills, [hahabird] was struck with the idea of making a giant-scale Spirograph that would (hopefully) be less frustrating for kids of all ages.

He generated the gears using an InkScape plugin, and then moved the project to Illustrator for adjustments. After nesting the inner gear drawings, he was able to print them out on one 3×3′ piece of paper at the local FedEx-Kinko’s. To make a template for routing he pieces that make up the eight-foot diameter outer ring, [hahabird] first cut it out of MDF and then bolted that to plywood. The outer ring’s size was dictated by the number of sections that fit on a 4×8 piece of plywood.

The challenge of the inner cogs was to make them move smoothly and still mesh with the teeth of the outer ring. [hahabird] solved this by mounting casters on raised platforms, which double nicely as handles. Each inner cog has a series of PVC couplers that take the 1″ PVC chalk holder insert.

So far, [hahabird] has cut 22-, 35-, and 44-tooth cogs, all of which are painted in nice, bright colors. According to his reddit comments, he will have a video or gif of it in a few days. We hope he makes the plus sign cog and the tongue depressor piece, too.