A CNC Woodworking Tool That Does The Hard Parts

Drawn along in the wake of the 3d printing/home shop revolution has been the accessibility of traditional subtractive CNC equipment, especially routers and mills. Speaking of, want a desktop mill? Try a Bantam Tools (née Othermachine) Desktop Milling Machine or a Carvey or a Carbide 3D Nomad. Tiny but many-axis general purpose mill? Maybe a Pocket NC. Router for the shop? Perhaps a Shapeoko, or an X-Carve, or a ShopBot, or a… you get the picture. [Rundong]’s MatchSticks device is a CNC tool for the shop and it might be classified as a milling machine, but it doesn’t quite work the way a more traditional machine tool does. It computer controls the woodworker too.

Sample joints the MatchSticks can cut

At a glance MatchSticks probably looks most similar to a Pocket NC with a big Makita router sticking out the side. There’s an obvious X-axis spoilboard with holes for fixturing material, mounted to a gantry for Z-axis travel. Below the big friendly handle on top is the router attached to its own Y-axis carriage. The only oddity might be the tablet bolted to the other side. And come to think of it the surprisingly small size for such an overbuilt machine. What would it be useful for? MatchSticks doesn’t work by processing an entire piece of stock at once (that what you’re for, adaptable human woodworker) it’s really a tool for doing the complex part of the job – joinery – and explaining to the human how to do the rest.

The full MatchSticks creation flow goes like this:

  1. Choose a design to make on the included interface and specify the parameters you want (size, etc).
  2. The MatchSticks tool will suggest what material stocks you need, and then ask you to cut them to size and prepare them using other tools.
  3. For any parts which require CNC work the tool will help guide the user to fixture the stock to its bed, then do the cutting itself.
  4. Once everything is ready for final assembly the MatchSticks will once again provide friendly instructions for where to pound the mallet.

In this way [rundong], [sarah], [jeremy], [ethan], and [eric] were able to build a much smaller machine tool without sacrificing much practical functionality. It’s almost software-like in it’s focus on a singular purpose. Why reinvent what the table saw can do when the user probably already has access to a table saw that will cut stock better? MatchSticks is an entire machine bent around one goal, making the hard stuff easier.

It’s worth noting that MatchSticks was designed as an exploration into computer/human interaction for the ACM Conference on Human Factors in Computing Systems so it’s not a commercial product quite yet (we’re eagerly waiting!). For a much more in depth look at the project and its goals and learnings the full research paper is available here. Their intro video is down after the break.

Thanks [ethan] for the tip!

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Soda Bottles Used as Heat-Shrink for Wood Joinery

Nobody is likely to confuse it with the beautiful joinery that makes fine furniture so desirable. But as a practical technique, using plastic bottles as heat-shrink tubing for composite joints is pretty nifty, and the pieces produced are not without their charm.

Undertaken as an art project to show people what can be done with recycled materials, [Micaella Pedros]’ project isn’t a hack per se. She started with bottles collected around London and experimented with ways to use them in furniture. The plastic used in soda and water bottles, polyethylene terephthalate (PET), turns out to shrink quite a bit when heated. Rings cut from bottles act much like large pieces of heat-shrink tubing, but with more longitudinal shrinkage and much more rigidity. That makes for a great structural component, and [Micaella] explored several ways to leverage the material to join wood. Notches and ridges help the plastic grip smoother pieces of wood, and of course the correct size bottle needs to be used. But the joints are remarkably strong – witness the classic leaning-back-in-a-chair test in the video below.

Its aesthetic value aside, this is a good technique to file away for more practical applications. Of course, there are plenty of ways to recycle soda bottles, including turning them into cordage or even using them as light-pipes to brighten a dark room.

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Woodworking Basics for the Hardware Hacker

Hackaday is primarily a place for electronics hackers, but that’s not to say that we don’t see a fair number of projects where woodworking plays a key role. Magic mirror builds come to mind, as do restorations of antique radios, arcade machines built into coffee tables, and small cases for all manner of electronic and mechanical gadgets. In some of these projects, the woodworking really shines and makes the finished project pop. In others — well, let’s just say that some woodwork looks good from far, but is far from good.

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Wooden Puzzle Book Will Twist and Dazzle Your Brain

In what might be one of the coolest applications of laser cutting, joinery, puzzles, writing, and bookbinding, [Brady Whitney] has created the Codex Silenda — a literal puzzle book of magnificent proportions.

[Whitney] had originally conceived the idea of the Codex for his senior thesis research project at Iowa State University, and the result is something for almost everyone. On each of the Codex’s five pages lies a mechanical puzzle that must be solved to progress to the next, while an accompanying text weaves a story as you do so. These intricate pages were designed in SolidWorks and painstakingly assembled from laser cut wood. Breaking the fourth wall of storytelling by engaging the reader directly in uncovering the book’s mysteries is a unique feat, and it looks gorgeous to boot.

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Add Slots and Tabs to Your Boxes in FreeCAD

FreeCAD is a fairly sophisticated, open-source, parametric 3D modeler. The open-source part means that you can bend it to your will. [Alexandre] is working on a module that lets him easily add tabs, finger joints, and t-slots to models (YouTube link, embedded down under).

Right now the plugin is still experimental, but it looks usable. In the video demo, [Alexandre] builds up a simple box, and then adds all manner of physical connective pieces to it. You’ll note that the tabs look like they’re pieces added on to the main face — that’s because they are! He then exports the outlines to SVG and erases the lines that separate the tabs from the sides, and hands these files off to his laser cutter. Voilà! A perfect tab-and-t-slot box, with only a little bit of hand-work. ([Alexandre] mentions that it’s all still very experimental and that you should check out your design before sending it to the laser.)

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Laser Cut Miter Joints

polyhedraEvery project deserves its own laser cut enclosure, of course, but the most common method of joinery – an overabundance of mortises and tenons, and if you’re lucky, a bit of kerf bending – is a little unsightly. Until tastes in industrial design change to accommodate this simple but primitive method of joining two laser cut panels together at an angle takes hold, the search will continue for a better way to cut acrylic and plywood on a laser cutter. The folks at Just Add Sharks might have a solution to this problem, though: miter joints with a laser cutter.

Instead of the slots and tabs of the usual method of constructing laser cut enclosures, miter joints produce a nearly seamless method of joining two perpendicular panels. The key, of course, is cutting a 45° bevel at the joint and gluing or fastening the pieces together. Just Add Sharks is doing this with a laser cut jig that holds a plywood or acrylic piece at a 45° angle to the laser beam. Yes, it’s only one cut per pass, but after adjusting the depth of cut to 1.4 times the thickness of the material, miter joints are easy.

Using a laser for miter joints isn’t limited to 45°, either. There are a few examples of an octahedron and icosahedron. Of course fastening these mitered panels together will be a challenge, but that’s what clamps and glue are for.

Foot-powered lathe is a tour de force of joinery techniques

foot-powered-lathe

Meet [Quetico Chris]. He’s a master woodworker who likes to find his own alternatives to using power tools. Most recently, he was inspired by a fly-wheel from an old factory. He used it to build this foot powered wood lathe.

It works something like a foot powered sewing machine. There’s a lever for your foot which converts the downward force from your foot into a rotating force which drives the work piece. The mechanics of the lathe are pretty common, but we think the build techniques he uses are anything but. The video after the break shows each step [Chris] went through when crafting the human-power tool. His approach was to use wood as often as possible which includes foregoing modern fasteners for older joinery. He uses mortise and tenon, wood pinning, doweling, and a lot of puzzle-like tricks to get the job done.

We lack the skill and tools to replicate this kind of craftsmanship. We’re going to stick to letting a laser cutter form our wood connections.

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