Autofeeding CNC Lathe Cranks Out Parts All By Itself

January 23, 2024 by Dan Maloney 18 Comments

The trouble with building a business around selling low-margin widgets is that you have to find a way to make a lot of them to make it worth your while. And if the widget in question is labor-intensive to make, you’ve got to find ways to reduce your inputs. That sounds like a job for industrial automation, a solution that’s often out of reach of small shops, for all the obvious reasons. Not if you’re clever about things, though, as this fully automated CNC lathe work cell shows.

This build comes to us from the woodshop of [Maher Lagha], where he’s making wooden honey dippers. Wooden dowel blanks are dispensed from an infeed rack and chucked between centers on the headstock and pneumatic tailstock. A two-axis stage in front of the workpiece moves a tool against the spinning stock, carving out the honey dipper in just a few minutes. When the lathe work is done, the spindle stops, the tailstock pulls the honey dipper back off the headstock, and a pneumatic piston unceremoniously whacks the almost-finished part — it looks like it still needs a little manual post-processing — into a bin. Lather, rinse, repeat, profit.

[Maher] doesn’t provide many details, but just looking at the work cell shows a veritable feast of industrial automation equipment. The spindle and tailstock of the lathe sit on a bed made from a massive slab of aluminum extrusion, and the X- and Y-axes use linear rails and ballscrews. And mindful of the effects of wood chips on delicate mechanisms, [Maher] did a good job of containing the mess with a host of acrylic guards.

As we said when we saw [Maher]’s wooden coaster work cell a while back, the wood widget business must be pretty good to justify automation like this. What’s nice with both these rigs is that they look like they could be quickly reprogrammed and retooled to create other products. Pretty impressive.

Continue reading “Autofeeding CNC Lathe Cranks Out Parts All By Itself” →

DIY Pneumatic Actuator Does Great In Action

December 23, 2023 by Lewin Day 5 Comments

Pneumatic actuators can be powerful and fast, making them very useful for all kinds of mechanical jobs. [Michael Rechtin] decided that while he could buy them off-the-shelf, he preferred to see if he could make his own via 3D printing. Despite the challenges, he succeeded!

Part of his success is because he knew when to take advantage of the strengths of 3D printed parts, and where they wouldn’t perform so well. To that end, the main body of the cylinder is actually a piece of PVC pipe. That’s because manufactured PVC pipe is far smoother and more regular than what you could reasonably achieve with a most 3D printers. The end caps, however, were printed and tapped to take standard air fittings. The piston was printed too, fitted with a steel cylinder rod and O-rings for sealing.

The double-acting cylinder performed remarkably well in testing, easily skewering an orange. The initial version did leak a touch, but later revisions performed better. Springs were also fitted for damping hits at either end which improved longevity, with a test rig racking up over 10,000 cycles without failure.

We love a design that is both easy to build at home and capable of great performance. We’ve featured some neat open-source pneumatic builds before, too.

Continue reading “DIY Pneumatic Actuator Does Great In Action” →

Automate Away The Drudgery Of CNC Manufacturing

June 25, 2023 by Dan Maloney 39 Comments

One of the keys to making money with manufacturing is to find something that you can make a lot of. Most small manufacturers have one or two “bread and butter” items that can be cranked out in quantity, which of course has a quality all its own. The problem with that approach, though, is that it runs the risk of being boring. And what better way to avoid that than by automating your high-volume job, with something like this automated CNC work cell?

[Maher Lagha] doesn’t offer too much in the way of build details, but the video below pretty much tells the tale. The high-volume items in this case are customized wooden coasters, the kind a restaurant would buy for their bar or a business would give away as swag. The small 3-axis CNC router at the center of the work cell is the perfect choice for making these — one at a time. With no desire to be tied to the machine all day to load raw stock and unload completed coasters, [Maher] came up with automated towers that hold stacks of pallets. Each pallet, which acts as a fixture for the workpiece through multiple operations, moves from the input stack into the router’s work envelope and to the output stack using a combination of servos and pneumatics. The entire work cell is about a meter on a side and contains everything needed for all the operations, including air for the pneumatics and dust extraction.

Each coaster requires two tools to complete — one for surfacing and one for lettering — and [Maher] has two ways to tackle that. The first is to allow a stack of coasters to go through the first operation, change tools, and switch the roughed-in stock back to the input stack for the second round of machining. The other is just to build another work cell dedicated to lettering, which seems to be in progress. In fact, it looks as if there’s a third work cell in the works in [Maher]’s shop. The coaster business must be pretty good.

Continue reading “Automate Away The Drudgery Of CNC Manufacturing” →

Compressed Air Keeps Screws Moving Through Modular Production System

April 27, 2023 by Dan Maloney 8 Comments

If there’s an unsung hero of manufacturing, it’s the engineer who figures out how to handle huge numbers of small parts. It’s one thing to manually assemble something, picking each nut, bolt, and washer by hand. It’s another thing to build a machine that can do the same thing, but thousands of times in a row, ideally without making mistakes.

Most of us don’t need that level of automation in our processes, but when you do, it results in some interesting challenges. Take this pneumatic screw accelerator that [Christopher Helmke] designed for his modular production system. One of the custom machines in his system is a screw counter, which uses a magnetic wheel to feed screws — or nuts or washers — from a hopper, orient them correctly, and drop them into an output chute. While the counting bit worked quite well, parts would only go so far under the force of gravity in the clear vinyl tube used to connect the counter to the next process.

[Christopher]’s solution was simple but effective. His first prototype simply injects compressed air into the parts feed tube, which pushes the screws through the tubing. It works surprisingly well, propelling the parts through quite a long length of tubing, handling twisting paths easily and even working against gravity. Version 2 integrated the accelerator and a re-orienting fixture into a single part, which mates with a magazine that holds a large number of screws.

There are a lot of interesting features [Christoper] built into these simple parts that are worth keeping in mind. Our favorite is printing channels to guide small cable ties around the tubing to clamp it into the accelerator. We’ll be keeping that trick in mind.

Continue reading “Compressed Air Keeps Screws Moving Through Modular Production System” →

Science Vs Internet Trolls: Testing Another Kind Of File System

November 24, 2021 by Dan Maloney 39 Comments

No matter what you do or say on the Internet, you’re always doing it wrong. Keyboard commandos are ready to pounce and tell you how it’s “ackchyually” supposed to be done. And so it was of little surprise when [Jason] of Fireball Tools was taken to task by the armchair millwright for his supposedly deficient method of filing metal.

But [Jason] chose to fight back not with words but deeds, building a system to test alternative methods of filing. His filing style is to leave the file in contact with the stock on both the front- and back-strokes, which enraged those who claim that a file must never be dragged back over the workpiece, lest the teeth become dull. The first video below shows the build of the test rig, which leveraged his enormous Cinncinatti shaper as the prime mover, as well as a pneumatic jig to hold the workpiece and imitate both styles of filing. Part two below shows the test rig in action, and [Jason] really outdoes himself with his experimental approach. He tested three different grades of Pferd files — nothing but the best, no expense spared — and did duplicates of each run using both the Internet-approved style and his lazier style.

The result? We won’t spoil that for you, but suffice it to say that the hive mind isn’t always right. And what’s more, [Jason]’s careful myth-busting yielded a few interesting and unexpected results. His channel is full of great shop tips and interesting builds, so check him out if you want to see how metalworking is done.

Continue reading “Science Vs Internet Trolls: Testing Another Kind Of File System” →

Soft Robotics Hack Chat

October 25, 2021 by Dan Maloney No comments

Join us on Wednesday, October 27 at noon Pacific for the Soft Robotics Hack Chat with Ali Shtarbanov!

By this point in technological history, we’ve all been pretty well trained in how to think about robots. Designs vary wildly, but to achieve their goals, most robots have one thing in common: they’re rigid. Whether it’s a robot arm slinging a spot welder on an assembly line or a robot dog on patrol, they’re largely made of stiff, strong, materials that, more often than not, are powered by electric motors of some sort.

But just because that’s the general design palette for robotics doesn’t mean there aren’t other ways. Robots, especially those that are intended to be used in close association with humans, can often benefit from being a little more flexible. And that’s where the field of soft robotics shines. Rather than a skeleton of machined aluminum and powerful electric actuators, these robots tend more toward silicone rubber construction with pneumatic activation. Some soft robots are even compliant and safe enough to be wearable, giving humans the ability to do things they never could before, or perhaps restoring functions that have been lost to the ravages of entropy.

Soft robotics is a fascinating field with the potential to really revolutionize things like wearables and collaborative robotics. To help us understand a little more about what’s going on in this space, we’re pleased to welcome Ali Shtarbanov to the Hack Chat. Ali is a Ph.D. student at MIT’s famed Media Lab, where he studies Human-Computer Interaction. He’s particularly interested in making soft robotics as fast and easy to prototype as traditional robotics have become, and to this end, he invented FlowIO, an open-source platform for pneumatic control. We’ll use this as a jumping-off point to discuss the whole field of soft robotics, especially where it is now and where Ali sees it going in the future.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, October 27 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

Extending bicycles can lift it's rider a meter into the air on four pneumatic pistons

Extending Bicycle Will Let You Stand Out Above The Crowd

September 2, 2021 by Danie Conradie 10 Comments

Some bicycles are built primarily for practicality, while others are more focused on novel looks. [Make It Extreme]’s latest project, the extending bicycle, falls squarely in the latter category.

Built around four custom-machined pneumatic pistons, this electric bike can lift the rider about a meter into the air with the flick of a switch. The front pair forms the bicycle’s forks, while the rear pair is mounted between the frame and swingarm. A small onboard compressor is used to charge a pair of modified fire extinguishers, which feed the pistons via pneumatic valves mounted on the handlebars. The wheels and brakes were scavenged from an old scooter. Since the length between the crankset and rear wheel never changes, there is no need to struggle with chain tensioners as the ride height changes.

While we would hate to face-plant from that height, it certainly looks like a fun ride and conversation starter. This is the case for many of [Make It Extreme]’s projects, like a ridable tank track and monowheel motorcycle.

Continue reading “Extending Bicycle Will Let You Stand Out Above The Crowd” →