Entry-Level 3D Printer Becomes Budget PCB Machine

November 27, 2017 by Dan Maloney 34 Comments

A funny thing happened on [Marco Rep]’s way to upgrading his 3D printer. Instead of ending up with a heated bed, his $300 3D printer can now etch 0.2-mm PCB traces. And the results are pretty impressive, all the more so since so little effort and expense were involved.

The printer in question is a Cetus3D, one of the newer generation of affordable machines. The printer has nice linear bearings but not a lot of other amenities, hence [Marco]’s desire to add a heated bed. But hiding beneath the covers was a suspicious transistor wired to a spare connector on the print head; a little sleuthing and a call to the factory revealed that the pin is intended for accessory use and can be controlled from G-code. With a few mods to the cheap UV laser module [Marco] had on hand, a printed holder for the laser, and a somewhat manual software toolchain, PCBs with 0.2-mm traces were soon being etched. The video below shows that the printer isn’t perfect for the job; despite the smooth linear bearings, the low mass of the printer results in vibration that shows up as wavy traces. But the results are more than acceptable, especially for $330.

This isn’t [Marco]’s first budget laser-etching rodeo. He recently tried the same thing using a cheap CNC laser engraver with similar results. That was a $200 dedicated engraver, this is a $300 3D printer with a $30 laser. It seems hard to lose at prices like these.

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Hacking A K40 Laser Cutter

November 22, 2017 by Jenny List 26 Comments

The distinctive blue-and-white enclosure of the Chinese-made K40 laser cutter has become a common sight in workshops and hackerspaces, as they represent the cheapest route to a working cutter that can be found. It’s fair to say though that they are not a particularly good or safe machine when shipped, and [Archie Roques] has put together a blog post detailing the modifications to make something better of a stock K40 performed at Norwich Hackspace.

After checking that their K40 worked, and hooking up suitable cooling and ventilation for it, the first task facing the Norwich crew was to install a set of interlocks. (A stock K40 doesn’t shut off the laser when you open the lid!) A switch under the lid saw to that, along with an Arduino Nano clone to aggregate this, a key switch, and an emergency stop button. A new front panel was created to hold this, complete a temperature display and retro ammeter to replace the modern original.

Norwich’s laser cutter has further to go. For example, while we secretly approve of their adjustable bed formed from a pile of beer mats, we concede that their plans to make something more practical have merit. The K40 may not be the best in the world, indeed it’s probable we should be calling it an engraver rather than a cutter, but if that means that a small hackerspace can have a cutter and then make it useful without breaking the bank, it’s good to see how it’s done.

This isn’t the first K40 enhancement we’ve featured. Norwich might like to look at this improved controller, or even extend their cutter’s bed. Meanwhile if [Archie]’s name rings a bell, it might be because of his Raspberry Pi laptop.

Less Than Production, More Than One-Offs

November 14, 2017 by Brian McEvoy 18 Comments

We build things we think are cool. Sometimes, other people agree with us and they want a copy of what we’ve built. If you’re lucky enough to have an enviable product but you’re not ready for full-scale manufacturing, you may be looking at a low-volume production run. [Eric Strebel] walks us through one such instance where he makes some custom color swatches for a show. Video after the break.

[Eric Strebel] is an industrial designer so he plays to his strengths by designing the swatch shape, jig, tool, and hangers. He hires out the painting, laser cutting, and CNC machining. This may seem like a simple statement but some of us have a hard time paying other people for things we’re capable of learning. In some cases, we just have to pay the professionals to do it correctly and keep our focus.

The mentality of small runs in this video is perfect for people who sell on Tindie or want to make more than a handful of consistently nice parts. Our own [Lewin Day] recently talked about his experience with a run of 200 mixers called gMix.

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Interference Scanner With Clear Instructions

October 25, 2017 by Brian McEvoy 13 Comments

Meticulous. Thorough. Exacting. These are all words we’d use to describe this video by [BrendaEM] about her Homemade 3D Optical Interference Scanner which can be seen after the break. The scanner uses 3D-printed parts and repurposed materials you might find lying around in your spare parts bin. An old optical drive tray acts to move the laser-wielding sled while a stripped-out webcam is an optical sensor. Links to relevant files such as 3D models and Arduino sketches will be found in the video’s author section.

The principle of operation is demonstrated with a water analog in the video at 2:00 with waves in a plastic container. By creating two small apertures between a light source and a sensor, it’s possible to measure the light waves which make it through. [BrendaEM] uses some powerful visualization software to convert her samples into 3D models which look really cool and simultaneously demonstrate the wave nature of light.

On the left side of her device are the control electronics which don’t need any special coatings since light won’t pass over this area. For the right side, where coherent light is measured, to borrow a Rolling Stones lyric: no colors anymore, I want them to turn black. Even the brass strips with apertures are chemically darkened.

Most of the laser hacks here use lasers rather than measure them, like this Laser Clock and a Laser Projector.

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NIST Uses Optical Resonance To Probe Atoms

October 2, 2017 by Al Williams 6 Comments

Have you ever stood under a dome and whispered, only to hear the echo of your voice come back much louder? Researchers at NIST used a similar principle to improve the atomic force microscope (AFM), allowing them to measure rapid changes in microscopic material more accurately than ever before.

An AFM works by using a minuscule sharp probe. The instrument detects deflections in the probe, often using a piezoelectric transducer or a laser sensor. By moving the probe against a surface and measuring the transducer’s output, the microscope can form a profile of the surface. The NIST team used a laser traveling through a circular waveguide tuned to a specific frequency. The waveguide is extremely close (150 nm) to a very tiny probe weighing about a trillionth of a gram. When the probe moves a very little bit, it causes the waveguide’s characteristics to change to a much larger degree and a photodetector monitoring the laser light passing through the resonator can pick this up.

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A Thoughtful Variety Of Projects And Failures

September 24, 2017 by Brian McEvoy 1 Comment

Our friends at [The Thought Emporium] have been bringing us delightful projects but not all of them warrant a full-fledged video. What does anyone with a bevy of small but worthy projects do? They put them all together like so many mismatched LEGO blocks. Grab Bag #1 is the start of a semi-monthly video series which presents the smaller projects happening behind the scenes of [The Thought Emporium]’s usual video presentations.

Solar eclipse? There are two because the first was only enough to whet [The Thought Emporium]’s appetite. Ionic lifters? Learn about the favorite transformer around the shop and see what happens when high voltage wires get too close. TEA lasers? Use that transformer to make a legitimate laser with stuff around your house. Bismuth casting? Pet supply stores may have what you need to step up your casting game and it’s a total hack. Failures? We got them too.

We first covered ionocraft (lifters) awhile back. TEA lasers have been covered before. Casting is no stranger to hackaday but [The Thought Emporium] went outside the mold with their technique.

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The Illuminated Waterways Of The United States

September 20, 2017 by James Hobson 8 Comments

A recent convert to the ways of the laser cutter, redditor [i-made-a-thing] was in want of a project and — stumbling on some waterways maps on Etsy — launched into fabricating an illuminated map of all the waterways in the United States.

The map itself was laser-cut out of 1/4 inch plywood at his local makerspace. Thing is, smaller rivers and tributaries were too narrow at the scale [i-made-a-thing] wanted, so he ended up spending several hours in Photoshop preparing the image so larger rivers would be laser-cut — and not break off– while the rest would be etched onto the surface. After testing the process by making a few coasters, he was ready to get started on the real deal.

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