lathe

170 Articles

Hacking When It Counts: DIY Prosthetics And The Prison Camp Lathe

July 14, 2025 by 13 Comments

There are a lot of benefits to writing for Hackaday, but hands down one of the best is getting paid to fall down fascinating rabbit holes. These often — but not always — delightful journeys generally start with chance comments by readers, conversations with fellow writers, or just the random largesse of The Algorithm. Once steered in the right direction, a few mouse clicks are all it takes for the properly prepared mind to lose a few hours chasing down an interesting tale.

I’d like to say that’s exactly how this article came to be, but to be honest, I have no idea where I first heard about the prison camp lathe. I only know that I had a link to a PDF of an article written in 1949, and that was enough to get me going. It was probably a thread I shouldn’t have tugged on, but I’m glad I did because it unraveled into a story not only of mechanical engineering chops winning the day under difficult circumstances, but also of how ingenuity and determination can come together to make the unbearable a little less trying, and how social engineering is an important a skill if you want to survive the unsurvivable.

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Clickspring’s Experimental Archaeology: Concentric Thin-Walled Tubing

April 25, 2025 by 32 Comments

It’s human nature to look at the technological achievements of the ancients — you know, anything before the 1990s — and marvel at how they were able to achieve precision results in such benighted times. How could anyone create a complicated mechanism without the aid of CNC machining and computer-aided design tools? Clearly, it was aliens.

Or, as [Chris] from Click Spring demonstrates by creating precision nesting thin-wall tubing, it was human beings running the same wetware as what’s running between our ears but with a lot more patience and ingenuity. It’s part of his series of experiments into how the craftsmen of antiquity made complicated devices like the Antikythera mechanism with simple tools. He starts by cleaning up roughly wrought brass rods on his hand-powered lathe, followed by drilling and reaming to create three tubes with incremental precision bores. He then creates matching pistons for each tube, with an almost gas-tight enough fit right off the lathe.

Getting the piston fit to true gas-tight precision came next, by lapping with a jeweler’s rouge made from iron swarf recovered from the bench. Allowed to rust and ground to a paste using a mortar and pestle, the red iron oxide mixed with olive oil made a dandy fine abrasive, perfect for polishing the metal to a high gloss finish. Making the set of tubes concentric required truing up the bores on the lathe, starting with the inner-most tube and adding the next-largest tube once the outer diameter was lapped to spec.

Easy? Not by a long shot! It looks like a tedious job that we suspect was given to the apprentice while the master worked on more interesting chores. But clearly, it was possible to achieve precision challenging today’s most exacting needs with nothing but the simplest tools and plenty of skill. Continue reading “Clickspring’s Experimental Archaeology: Concentric Thin-Walled Tubing” →

A man in black glasses and a black t-shirt has his arms resting on a grey workbench. Between his opened hands are the two halves of a copper ice press. They are fist-sized copper cylinders. The lower half has large spiraling grooves to aid in the release of excess water from the ice being formed as it melts.

Make Ice Spheres In A Copper Press

March 2, 2025 by 11 Comments

Perfectly clear ice spheres are nifty but can be a bit tricky to make without an apparatus. [Seth Robinson] crafted a copper ice press to make his own.

Copper is well-known for its thermal conductivity, making it a perfect material for building a press to melt ice into a given shape. Like many projects, a combination of techniques yields the best result, and in this case we get to see 3d printing, sand casting, lost PLA casting, lathe turning, milling, and even some good old-fashioned sanding.

The most tedious part of the process appears to be dip coating of ceramic for the lost PLA mold, but the finished result is certainly worth it. That’s not to say that any of the process looks easy if you are a metal working novice. Taking over a week to slowly build up the layers feels a bit excruciating, especially compared to 3D printing the original plastic piece. If you’re ever feeling discouraged watching someone else’s awesome projects, you might want to stick around to the end when [Robinson] shows us his first ever casting. We’d say his skill has improved immensely over time.

If you’re looking for something else to do with casting copper alloys, be sure to checkout this bronze river table or [Robinson’s] copper levitation sphere.

Thanks to [DjBiohazard] for the tip!

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Lathe And Laser Team Up To Make Cutting Gear Teeth Easier

February 14, 2025 by 25 Comments

Fair warning: watching this hybrid manufacturing method for gear teeth may result in an uncontrollable urge to buy a fiber laser cutter. Hackaday isn’t responsible for any financial difficulties that may result.

With that out of the way, this is an interesting look into how traditional machining and desktop manufacturing methods can combine to make parts easier than either method alone. The part that [Paul] is trying to make is called a Hirth coupling, a term that you might not be familiar with (we weren’t) but you’ve likely seen and used. They’re essentially flat surfaces with gear teeth cut into them allowing the two halves of the coupling to nest together and lock firmly in a variety of relative radial positions. They’re commonly used on camera gear like tripods for adjustable control handles and tilt heads, in which case they’re called rosettes.

To make his rosettes, [Paul] started with a block of aluminum on the lathe, where the basic cylindrical shape of the coupling was created. At this point, forming the teeth in the face of each coupling half with traditional machining methods would have been tricky, either using a dividing head on a milling machine or letting a CNC mill have at it. Instead, he fixtured each half of the coupling to the bed of his 100 W fiber laser cutter to cut the teeth. The resulting teeth would probably not be suitable for power transmission; the surface finish was a bit rough, and the tooth gullet was a little too rounded. But for a rosette, this was perfectly acceptable, and probably a lot faster to produce than the alternative.

In case you’re curious as to what [Paul] needs these joints for, it’s a tablet stand for his exercise machine. Sound familiar? That’s because we recently covered his attempts to beef up 3D prints with a metal endoskeleton for the same project.

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Modulathe Is CNC Ready And Will Machine What You Want

January 20, 2025 by 14 Comments

Once upon a time, lathes were big heavy machines driven by massive AC motors, hewn out of cast iron and sheer will. Today, we have machine tools of all shapes and sizes, many of which are compact and tidy DIY creations. [Maxim Kachurovskiy]’s Modulathe fits the latter description nicely.

The concept behind the project was simple—this was to be a modular, digital lathe that was open-source and readily buildable on a DIY level, without sacrificing usability. To that end, Modulathe is kitted out to process metal, wooden, and plastic parts, so you can fabricate in whatever material is most appropriate for your needs.

It features a 125 mm chuck and an MT5 spindle, and relies on 15 mm linear rails, 12 mm ball screws, and NEMA23 stepper motors. Because its modular, much of the rest of the design is up to you. You can set it up with pretty much any practical bed length—just choose the right ball screw and rail to achieve it. It’s also set up to work however you like—you can manually operate it, or use it for CNC machining tasks instead.

If you want a small lathe that’s customizable and CNC-ready, this might be the project you’re looking for. We’ve featured some other similar projects in this space, too. Do your research, and explore! If you come up with new grand machine tools of your own design, don’t hesitate to let us know!

Thanks to [mip] for the tip!

Lathe Gears Make A Clock

December 27, 2024 by 11 Comments

When you think of making something using a lathe,  you usually think of turning a screw, a table leg, or a toothpick. [Uri Tuchman] had a different idea. He wanted to make a clock out of the gears used in the lathe. Can he do it? Of course, as you can see in the video below.

Along the way, he used several tools. A mill, a laser cutter, and a variety of hand tools all make appearances. There’s also plenty of CAD. Oh yeah, he uses a lathe, too.

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Hackaday Links: December 22, 2024

December 22, 2024 by 11 Comments

Early Monday morning, while many of us will be putting the finishing touches — or just beginning, ahem — on our Christmas preparations, solar scientists will hold their collective breath as they wait for word from the Parker Solar Probe’s record-setting passage through the sun’s atmosphere. The probe, which has been in a highly elliptical solar orbit since its 2018 launch, has been getting occasional gravitational nudges by close encounters with Venus. This has moved the perihelion ever closer to the sun’s surface, and on Monday morning it will make its closest approach yet, a mere 6.1 million kilometers from the roiling photosphere. That will put it inside the corona, the sun’s extremely energetic atmosphere, which we normally only see during total eclipses. Traveling at almost 700,000 kilometers per hour, it won’t be there very long, and it’ll be doing everything it needs to do autonomously since the high-energy plasma of the corona and the eight-light-minute distance makes remote control impossible. It’ll be a few days before communications are re-established and the data downloaded, which will make a nice present for the solar science community to unwrap.

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