Enresoning An iPhone 8 Ring

The iPhone 8 was just released last week, and that means some people were standing in line in front of an Apple store for hours waiting to get their hands on the latest and greatest glowing rectangle. [Patrick Adair] had a better idea: he would stand in front of an Apple store for four hours, then do something productive with his new smartphone. With the help of a waterjet, some resin, a lathe, and some very fine grades of sandpaper, he created the Apple Ring.

Setting aside the whole process of actually acquiring an iPhone 8 on launch day, the process of turning an iPhone into a ring is more or less what you would expect. First, the iPhone was cut into ring-shaped pieces on a waterjet cutter. Special care was taken to avoid the battery, and in the end [Patrick] was able to get a nice chunk ‘o phone that included the camera lens.

This ring piece was then embedded in clear resin. For this, [Patrick] used Alumilite epoxy, a pressure pot, and a toaster oven to cure the resin. Once the phone parts were firmly encased for the rest of eternity, the ring blank moved over to the lathe. The center of the ring was bored out, and the process of sanding, polishing and gluing in all the tiny parts that fell out during the process commenced. The end result actually looks pretty great, and even though it’s probably a little too bulky, it is a remarkable demonstration of the craft of turning.

You can check out [Patrick]’s video below, along with a video from the Waterjet Channel showing the deconstruction of a glowing rectangle.

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The Illuminated Waterways of the United States

A recent convert to the ways of the laser cutter, redditor [i-made-a-thing] was in want of a project and — stumbling on some waterways maps on Etsy — launched into fabricating an illuminated map of all the waterways in the United States.

The map itself was laser-cut out of 1/4 inch plywood at his local makerspace. Thing is, smaller rivers and tributaries were too narrow at the scale [i-made-a-thing] wanted, so he ended up spending several hours in Photoshop preparing the image so larger rivers would be laser-cut — and not break off– while the rest would be etched onto the surface. After testing the process by making a few coasters, he was ready to get started on the real deal.

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Casting Metal Directly Into 3D Printed Molds

Casting metal and 3D printing go together like nuts and gum, and there are no shortage techniques that use the two together. Lost PLA casting is common, and sculptors are getting turned on to creating their works in plastic first before sending it off to the foundry. Now the folks at FormLabs have turned the whole ‘casting metal and 3D printer’ thing on its head: they’re printing sacrificial molds to cast pewter.

There are two techniques demonstrated in this tutorial, but the real winner here is printing a complete sacrificial mold for pewter miniatures. While this technique requires a little bit of work including washing, curing, and a bit of post-processing, you would have to do that anyway with anything coming out of a resin printer.

The material of choice for these molds is a high temp resin with a heat deflection temperature of 289 °C. Using a pewter alloy that melts at 260 °C, casting a metal miniature is as simple as pouring molten metal into a mold. Demolding might be a little finicky, but with a small screwdriver used as a chisel, it’s possible to get the cast newly parts out.

We’ve seen pewter casting with PLA, but the quality available from the Form resin printers is truly amazing and produces some great looking miniatures.

A Great Way to Make Quick and Easy Knobs

Here’s a great way to quickly and easily make attractive and functional knobs with no tools required. All you need is some casting resin (epoxy would do in a pinch), a silicone mold intended for candy, and some socket head bolts. With the right preparation and a bit of careful placement and attention, smooth and functional knob ends are only minutes away. Embedded below is a short video demonstrating the process.

These may not replace purpose-made knobs for final products, but for prototypes or to use around the shop on jigs, clamps, or furniture they certainly fit the bill. With a layer of adhesive fabric or rubber, they might even make serviceable adjustable feet for low-stress loads.

This technique could be extended to reproducing broken or missing dakaware or bakelite knobs. This, of course, would require an original, unbroken knob and a small silicone mold, but it’s still a project that’s well within the capabilities of the garage-bound hacker.

While we’re on the subject of knobs, don’t forget we’ve seen an excellent method of repairing knobs as well.

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How to Do Beautiful Enclosures with Custom Fiberglass

There are times when I feel the need to really make a mess. When I think of making messes with a degree of permanency, I think of fiberglass. I also really like the smell, reminds me of a simpler time in 8th grade shop class. But the whole process, including the mess, is worth it for the amazing shapes you can produce for speaker pods and custom enclosures.

Utilizing fiberglass for something like a custom speaker pod for a car is not difficult, but it does tend to be tedious when it comes to the finishing stages. If you have ever done bodywork on a car you know what kind of mess and effort I am talking about. In the video below, I make a simple speaker pod meant for mounting a speaker to the surface of something like a car door.

You can also use a combination of wood and fiberglass to make subwoofer cabinets that are molded to the area around them. You can even replace your entire door panel with a slick custom shaped one with built in speakers  if you’re feeling adventuresome.

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Hackaday Prize Entry: DIY LCD based SLA 3D Printer

Resin-based SLA 3D printers are seen more and more nowadays but remain relatively uncommon. This Low Cost, Open Source, LCD based SLA 3D Printer design by [Dylan Reynolds] is a concept that aims to make DIY SLA 3D printing more accessible. The idea is to use hardware and manufacturing methods that are more readily available to hobbyists to create a reliable and consistent DIY platform.

[Dylan]’s goal isn’t really to compete with any of the hobbyist or prosumer options on the market; it’s more a test bed for himself and others, to show that a low-cost design that takes full advantage of modern hardware like the Raspberry Pi can be made. The result would be a hackable platform to let people more easily develop, experiment, or simply tamper with whatever part or parts they wish.

A Big 3D Printer Built Using The Power of Procrastination

When we wrote about [Dan Beaven]’s resin printer a while back he enthusiastically ensured us that, thanks to the recent wave of attention, he would finally finish the project. That’s why today we are covering his entirely unrelated 2 cubic foot print volume FDM printer. 

As we mentioned, [Dan] is no stranger to 3D printers. His addiction has progressed so far that he needs bigger and bigger parts, but when he looked at the price of printers that could sate his thirst… it wasn’t good. We assume this is the time he decided to leverage his resin printer procrastination to build a massive printer for himself.

The frame is aluminum extrusion. The bed is an 1/4″ thick aluminum plate supported just a little bit in from each corner. He can use the 4 motors to level the platform, which is a killer feature on a machine this big. More or less it’s fairly standard mechanically.

We are interested in his interesting addition of a FLIR thermal sensor to see live heat distribution. We also applaud him on his redundant safety systems (such as a smoke sensor that’s separately powered from the machine).

All the files are available on his site if you’re procrastinating on something and would like one for yourself.