Even for the simplest of products, production at scale can be big challenge. For example, you might find yourself spending many hours manually counting and cutting strips of component tape to go with the DIY electronics kit your selling on Tindie. [Tom Keddie] found himself in similar position some time ago, and built himself an automated component counter and tape cutter.
[Tom] posted the video of his old machine (see it after the break) after a call for help from another Twitter user who found himself with a lot of component strips to cut. The frame of the machine is made from 20×20 aluminium extrusions and laser cut plexiglass. The tape is pulled off the reel by a stepper motor using a 3D printed sprocket, with the tape held on by Lego wheel and tension spring. A second idler sprocket with tensioner is used to guide the tape through two photo-interrupters that can count holes in opaque tape or the components in clear tape. The cutter itself it an Exacto blade mounted on a wooden block in a guillotine-like arrangement, driven by another stepper motor and a threaded rod as lead screw. Everything is of course controlled by an Arduino. Although not used any more, [Tom] says it worked very well in its day.
The availability of cheap laser cutting, 3D printing and components like aluminium extrusions and stepper motors have really made it possible for anyone to add some automation to production in the home workshop. You won’t be surprised that we’ve seen something like this before, but we’ve also seen similar machines for wiring prep and through-hole resistors. Let us hear your production hacks in the comments, or drop us a tip if you’ve documented it!
Continue reading “Automatic Component Tape Cutter For When Your Electronics Kit Hits The Big Time”
The production capability available to the individual hacker today is really quite incredible. Even a low-end laser engraver can etch your PCBs, and it doesn’t take a top of the line 3D printer to knock out a nice looking enclosure. With the wide availability of these (relatively) cheap machines, the home builder can churn out a very impressive one-off device on a fairly meager budget. Even low volume production isn’t entirely out of the question. But there’s still one element to a professional looking device that remains frustratingly difficult: a good looking front panel.
Now if your laser is strong enough to engrave (and ideally cut) aluminum sheets, then you’ve largely solved this problem. But for those of us who are plodding along with a cheap imported diode laser, getting text and images onto a piece of metal can be rather tricky. On Hackaday.io, [oaox] has demonstrated a cost effective way to create metal front panels for your devices using a print service that offers Dibond aluminum. Consisting of two thin layers of aluminum with a solid polyethylene core, this composite material was designed specifically for signage. Through various online services, you can have whatever you wish printed on a sheet of pre-cut Dibond without spending a lot of money.
As explained by [oaox], the first step is putting together the image you’ll send off to the printer using a software package like Inkscape. The key is to properly define the size of the Dibond plate in your software and work within those confines, otherwise the layout might not look how you expected once the finish piece gets back to you. It’s also important to avoid lossy compression formats like JPEG when sending the file out for production, as it can turn text into a mushy mess.
When you get the sheet back, all you need to do is put your holes in it. Thanks to the plastic core, Dibond is fairly easy to cut and drill as long as you take your time. [oaox] used a step drill for the holes, and a small coping saw for the larger openings. The final result looks great, and required very little effort in the grand scheme of things.
But how much does it cost? Looking around online, we were quoted prices as low as $7 USD to do a full-color 4×4 inch Dibond panel, and one site offered a 12×12 panel for $20. For a small production run, you could fit several copies of the graphics onto one larger panel and cut them out with a bandsaw; that could drop the per-unit price to only a couple bucks.
We’ve seen some clever attempts at professional looking front panels, from inkjet printing on transparencies to taking the nuclear option and laser cutting thin plywood. This is one of those issues the community has been struggling with for years, but at least it looks like we’re finally getting some decent options.
Pogo pins – spring-loaded pin contacts are pretty fun to play with and even cooler when they get used in electronic devices like Adafruit and SparkFun’s test jigs. Check after the break for how these two companies have created their own production hacks. Continue reading “Test Beds And Jigs With Pogo Pins”