A large silver cone attached to a black hemisphere floats over a piece of sheet metal held in a metal frame. The metal has what appears to be machine grease on it to aid in the forming process.

CNC Metal Forming

Forming complex shapes in metal sheets is still a laborious process, especially if you aren’t needing more than a couple parts so stamping doesn’t make sense. That may change with Digital Sheet Forming.

While this video is basically an ad for one vendor’s approach, it gives a good set of examples of what the technique can achieve. The high pressure mechanism of the machine presses the metal layer by layer down against a silicone backing to form what you’ve designed, in this case, the nose cone for a Tucker Carioca.

Some people will decry it killing the metal forming industry, but as [Rob Ida] says in the video, it will allow metal formers to become more efficient at the work they do by taking out the tedium and letting them focus on the parts of the process requiring the most skill. Anyone who’s done any work with a 3D printer or CNC mill will know that sending a file to a machine is only one small part of the process.

We’re anxious to see this technology make its way to the makerspace and home shop. If you want to do some sheet metal forming now, why not try hydroforming?

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So, You’ve Never Made A Spaceframe Before

It is sometimes a surprise in our community of tinkerers, builders, hackers, and makers, to find that there are other communities doing very similar things to us within their own confines, but in isolation to ours. A good example are the modified vehicle crowd. In their world there are some epic build stories and the skills and tools they take for granted would not in any way be unfamiliar to most Hackaday readers.

As part of a discussion about electric vehicles near where this is being written, someone tossed an interesting link from that quarter into the mix; a two-part treatise on building ultra-light-weight tubular frame vehicles. Or space frames, as you might know them.

You might think that making a tubular framed for a vehicle would be a straightforward enough process, but as the article explains, it contains within it a huge well of geometry and metallurgy to avoid a creation that is neither too heavy nor contains excessive weakness. Part one deals mainly with prototyping a frame, the selection of materials and joining tubes, while part two goes into more detail on fabrication. The author likes brazing which may offend the sensibilities of welding enthusiasts, but you can substitute your jointing tech of choice.

A particularly neat suggestion, one of those simple ideas that make you wish you’d thought of it yourself, is to prototype a frame in miniature with copper wire and solder to evaluate the effect of different forces upon it before you commit your final design to steel.

The articles are a few years old, but no less pertinent in the information they contain. Meanwhile if you are a spaceframe veteran, then you may have your own suggestions for the comments below. And if you’d like some tips on how not to build a spaceframe, have a look at this motorcycle.

Thank you [JHR] and [Jarkman] for the tips.

Metalworking Hacks Add Functionality To Snap-On Tool Chest

Problem: you’re a student mechanic and you’ve already poured a ton of money into a Snap-On roller cabinet loaded with the tools of the trade, but you still need sensible storage for your cordless tools. Solution: a DIY version of Snap-On’s PowerCab cordless tool station at a fraction of the cost.

rnqvgsoMechanics seem to have a love-hate relationship with Snap-On tools. Some love the brand, others hate it, but the majority seem to hate that they love the tools. It sounds like [GenTQ] reached her limit on brand loyalty when even her 50% student discount wasn’t enough to entice her to add Snap-On’s admittedly very cool KRL1099 cabinet for cordless drivers and chargers. So it was off to Harbor Freight for their seven-drawer side cabinet for less than $200. The cabinet was gutted of drawers, a frame for the new slide-out was welded up, and sheet steel was fabricated into organizer shelves and a new drawer front. A power strip and drag-chain were added to feed the chargers, and the new drawer went off to the powder coater for a matching paint job.

It may not have the Snap-On badge, and purists may cringe at the mixed-marriage with Horror Fright, but we like the results just fine. And she saved something like $1200 in the process. We think Harbor Freight gets a bad rap, deservedly so for some tools, but there are hidden gems amid the dross just ripe for the hacking, as [GenTQ] ably shows.

[via r/DIY]

Denver Mini Maker Faire Roundup

I had a great time at Denver’s 3rd annual Mini Maker Faire, which was held inside the Denver Museum of Nature and Science. The official theme this year was “Building the Future” and looking back, I can tell you that they pulled the theme off well. There was a strong turnout in two categories that are crucial to building the future: the growth that comes from education at all ages and the physical places where learning becomes immersive.

The Really Fun Stuff

poison arrow[Casey] from Caustic Creations were showing off Poison Arrow just in time for season 2 of the BattleBots reboot. Poison Arrow is 250-lb. drum spinner that destroys things at 9,000 RPM. Here’s a nice introductory video shot by their sponsor, Arrow Electronics. [Casey] told me that Poison Arrow will be on the June 30th episode, so set your DVR.

Who knew that Colorado had so many maker- and hackerspaces? Colorado Makerhub, that’s who. They provide a portal to everything maker-related in Colorado, and they were in attendance along with most of the ‘spaces within a 50-mile radius of the city. Denver’s own Denhac brought a huge multiplayer rig that they had built for Comic Con last year. It runs Artemis, a spaceship bridge simulator game that divides up the tasks necessary for successful intergalactic travel. Here’s a video of Denhac member [Radio Shack] describing the game and giving a tour of one of the consoles. The group landed a space in one of the darker areas of the museum, which made the blinkenlights irresistible, especially to boys of a certain age range.

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