Punch Those Hole-Drilling Blues Away With A Homebrew Punching Tool

Four times the holes, four times the trouble. With the fate of repetitive motion injury looming due to the need to drill 1,200 holes, [bitluni] took matters into his own hands and built this nifty DIY hole punch for light-gauge sheet metal.

A little backstory will probably help understand why [bitluni] needs so many holes. Back in May, he built a ping pong ball LED video wall for Maker Faire Berlin. That had 300 LEDs and came out great, but at the cost of manually drilling 300 holes in sheet steel with a hand drill. Looking to expand his wall of balls to four times the original size, [bitluni] chose to spend a few days building a punch to make the job more appealing. The business end, with solid bar stock nested inside pieces of tubing, is a great example of how much you can get done without a lathe. The tool is quite complex, with a spring-loaded pilot to help guide the punching operation. When that proved impractical, [bitluni] changed the tool design and added an internal LED to project crosshairs from inside the tool.

The tool itself is mounted into a sturdy welded steel frame that allows him to cover the whole aluminum sheet that will form the panel of his LED wall. It’s pretty impressive metalwork, especially considering this isn’t exactly in his wheelhouse. And best of all, it works – nice, clean holes with no deformation, and it’s fast, too. We’re looking forward to seeing the mega-LED wall when it’s done.

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Punch The World With A Raspberry Pi

Robots have certainly made the world a better place. Virtually everything from automobile assembly to food production uses a robot at some point in the process, not to mention those robots that can clean your house or make your morning coffee. But not every robot needs such a productive purpose. This one allows you to punch the world, which while not producing as much physical value as a welding robot in an assembly line might, certainly seems to have some therapeutic effects at least.

The IoT Planet Puncher comes to us from [8BitsAndAByte] who build lots of different things of equally dubious function. This one allows us to release our frustration on the world by punching it (or rather, a small model of it). A small painted sphere sits in front of a 3D-printed boxing glove mounted on a linear actuator. The linear actuator is driven by a Raspberry Pi. The Pi’s job doesn’t end there, though, as the project also uses a Pi camera to take video of the globe and serve it on a webpage through which anyone can control the punching glove.

While not immediately useful, we certainly had fun punching it a few times, and once a mysterious hand entered the shot to make adjustments to the system as well. Projects like this are good fun, and sometimes you just need to build something, even if it’s goofy, because the urge strikes you. Continue reading “Punch The World With A Raspberry Pi”

3D-Printed Punch And Die Stand Up To Steel

When you think of machine tooling, what comes to mind might be an endmill made of tungsten carbide or a punch and die made of high-speed steel. But surely there’s no room in the machine tool world for 3D-printed plastic tools, especially for the demanding needs of punching parts from sheet metal.

As it turns out, it is possible to make a 3D-printed punch and die set that will stand up to repeated use in a press brake. [Phil Vickery] decided to push the tooling envelope to test this, and came away pleasantly surprised by the results. In fairness, the die he used ended up being more of a composite between the carbon-fiber nylon filament and some embedded metal to reinforce stress points in the die block. It looks like the punch is just plastic, though, and both were printed on a Markforged Mark 2, a printer specifically designed for high-strength parts. The punch and die set were strong enough to form 14-gauge sheet steel in a press brake, which is pretty impressive. The tool wasn’t used to cut the metal; the blanks were precut with a laser before heading to the press. But still, having any 3D-printed tool stand up to metal opens up possibilities for rapid prototyping and short production runs.

No matter what material you make your tooling out of, there’s a lot to know about bending metal. Check out the basics in our guide to the art and science of bending metal.

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Music Box Plays “Still Alive” Thanks To Automated Hole Puncher

Custom hole punch and feed system

Most projects have one or two significant aspects in which custom work or clever execution is showcased, but this Music Box Hole Punching Machine by [Josh Sheldon] and his roommate [Matt] is a delight on many levels. Not only was custom hardware made to automate punching holes in long spools of paper for feeding through a music box, but a software front end to process MIDI files means that in a way, this project is really a MIDI-to-hand-cranked-music-box converter. What a time to be alive.

The hole punch is an entirely custom-made assembly, and as [Josh] observes, making a reliable hole punch turns out to be extremely challenging. Plenty of trial and error was involved, and the project’s documentation as well as an overview video go into plenty of detail. Don’t miss the music box version of “Still Alive”, either. Both are embedded below.

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Punching Accelerometers

Shortly after finishing his Makiwara punching bag, [Abieneman] wired and programmed an Arduino to an accelerometer to find out just how much acceleration (and with some math, force) is behind his punches. The project is simple and would be quick to reproduce for your own measuring and experiments: all that he used included an Arduino, accelerometer (with A/D converter), LED displays (and shift register). We were a little disappointed to learn of how much static the accelerometer produced, so measuring things such as impulse, energy, and pretty much anything not kinematic is nullified. But it makes us wonder, how much static would be in say, a Wii Remote punching bag?

Punchy Punchout, Improved

[Sam] submitted this fun project, a Punchout interface that you actually punch. If you recall, we’ve done a Punchout interface that you punch, but this one takes it a step further. Instead of being a blob on a desk that you’re mashing around, the new one is a Slam Man boxing dummy. They’ve mounted the buttons on different areas of the dummy so you can punch him to completely control the game. As you can see in the video, it seems to work ok, though we doubt the buttons will hold up very long under those conditions. They do say that this is just to hold them over till the Wii version, so maybe those buttons will last just long enough.

Punchy Punchout Controller

punchy_mcpunchpunch

We love alternative inputs. They can revitalize an old classic or add a twist to most any mundane task. Here, we see a perfect example where the game Punch Out for the NES is being controlled by a punching bag type thing. The impact sensors were made by hand, and wired to a PC game pad. They were mounted on some foam, allowing for a nice mushy punching surface.  There’s some feedback too, when your character is hit, a custom script detects the change in the sprites color and sends a signal to an Arduino. Right now, it just lights an LED, but the goal is to signal a strobe to make you flinch. This looks like it would be fun to play with, especially if you were to make it a little more high impact.  You can see a video of them lightly assaulting it after the break.

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