Torque Testing 3D Printed Screws

December 3, 2024 by Dan Maloney 18 Comments

Unless you’ve got a shop with a well-stocked hardware bin, it’s a trip to the hardware store when you need a special screw. But [Sanford Prime] has a different approach: he prints his hardware, at least for non-critical applications. Just how much abuse these plastic screws can withstand was an open question, though, until he did a little torque testing to find out.

To run the experiments, [Sanford]’s first stop was Harbor Freight, where he procured their cheapest digital torque adapter. The test fixture was similarly expedient — just a piece of wood with a hole drilled in it and a wrench holding a nut. The screws were FDM printed in PLA, ten in total, each identical in diameter, length, and thread pitch, but with differing wall thicknesses and gyroid infill percentages. Each was threaded into the captive nut and torqued with a 3/8″ ratchet wrench, with indicated torque at fastener failure recorded.

Perhaps unsurprisingly, overall strength was pretty low, amounting to only 11 inch-pounds (1.24 Nm) at the low end. The thicker the walls and the greater the infill percentage, the stronger the screws tended to be. The failures were almost universally in the threaded part of the fastener, with the exception being at the junction between the head and the shank of one screw. Since the screws were all printed vertically with their heads down on the print bed, all the failures were along the plane of printing. This prompted a separate test with a screw printed horizontally, which survived to a relatively whopping 145 in-lb, which is twice what the best of the other test group could manage.

[Sanford Prime] is careful to note that this is a rough experiment, and the results need to be taken with a large pinch of salt. There are plenty of sources of variability, not least of which is the fact that most of the measured torques were below the specified lower calibrated range for the torque tester used. Still, it’s a useful demonstration of the capabilities of 3D-printed threaded fasteners, and their limitations.

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Remove Wall Plugs Fast With A Custom Tool

April 18, 2024 by Lewin Day 39 Comments

The best thing about buying your own home is that you can hang things on the walls. It’s a human right all too often denied to renters the world over. Regardless, five years later, when you’re doing the mandatory minimalist remodel, you’ll be ruing the day you put in all those wall anchors. At that point, consider removing them with this nifty tool from [XDIY with Itzik].

The design aims to remove wall anchors as cleanly as possible. It’s easiest to watch the video to get the idea of how it works.

The tool features a block which holds a bearing. That bearing acts as a rotating stop for a wood screw. The idea is that you place the block against the wall, and use a power drill to drive a wood screw into the anchor at high speed. The screw can’t move forward, so the threads basically yank the plug out of the wall, and relatively neatly at that. Once removed, there’s a little push stopper you can use to hold the old plug in place as you remove the wood screw from the device, ready to go again.

[Itzik] demonstrates the device by removing ten wall plugs in just 40 seconds. If you’ve got a lot to do, or it’s a job you do regularly, you might like to have this tool in your kit.

Oftentimes, having the right tool can make a job ten times faster, and this seems like one of those cases. Video after the break.

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The Nuts And Bolts Of Nuts And Bolts

April 28, 2023 by Dan Maloney 23 Comments

If you’re a mechanical engineer, the material covered in this video on the basics of bolted joints probably won’t cover any new ground. On the other hand, if you aren’t a mechanical engineer but still need to bring a little of that discipline to your projects, there’s a lot to learn here.

If there’s one takeaway lesson from [The Efficient Engineer]’s excellent examination of the strength of bolted joints, it’s the importance of preload. Preload is the tensile force created by tightening a bolt or a screw, which provides the clamping force that keeps the joined members together. That seems pretty self-obvious, but there’s more to the story, especially with joints that are subject to cycles or loading and unloading. Such joints tend to suffer from fatigue failure, but proper preloading on the bolts in such a joint mitigates fatigue failure because the bolts are only taking up a small fraction of the total cyclical force on the joint. In other words, make sure you pay attention to factory torque specs.

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Renaissance-Style Drone Would Make Da Vinci Proud Four Times Over

February 1, 2022 by Dan Maloney 7 Comments

For as much of a genius as Leonardo da Vinci obviously was, modern eyes looking upon his notebooks from the 1400s tend to see his designs as somewhat quaint. After all, his concept of a vehicle armored with wood would probably only have survived the archers and pikemen of a Renaissance battlefield, and his curious helicopter driven by an Archimedes screw would certainly never fly, right?

Don’t tell that to [Austin Prete] and his team from the University of Maryland, who’ve built a da Vinci-style quadcopter that actually flies. Called the “Crimson Spin”, the quad is based on a standard airframe and electronics. Details are sparse — the group just presented the work at a vertical flight conference — but it appears the usual plastic props are replaced with lightweight screws made from wire and some sort of transparent plastic membrane. Opposing pairs of screws have the opposite handedness, which gives the quad yaw control. There’s a video embedded in the link above that shows the quad being tested both indoors and out, and performing surprisingly well. We’d imagine that Crimson Spin might not do so well on a windy day, given the large wind cross-section those screws present, but the fact it got off the ground at all is cool enough. It kind of makes you wonder where we’d be today if da Vinci had access to BLDCs.

For as fanciful as da Vinci’s designs can be, we’ve seen a fair number of attempts to recreate them in modern materials. His cryptex is a perennial favorite for hackers, and his bizarre piano-esque “viola organista” has been attempted at least once.

Thanks to [Peter Ryseck] for this tip.

Better Mousetraps (or Screw Drives) Don’t Always Win

August 4, 2021 by Al Williams 114 Comments

I’ve noticed, lately, that slotted screw heads are all but gone on new equipment. The only thing that I find remarkable about that is that it took so long. While it is true that slotted heads have been around for ages, better systems are both common and have been around for at least a century.

The reason slotted heads — technically known as the drive — are so common is probably because they are very easy to make. A hacksaw is sufficient for the job and there are other ways to get there, too. The only advantages I know of for the user is that you can easily clean a slotted drive and — possibly — use field expedient items like butter knives and quarters to turn the screw. I’ve heard people claim that it also is a feature that the screwdriver can pry things like paint can lids, but that’s a feature of the tool, not the screw drive.

The disadvantages, though, are significant. It is very hard to apply lots of torque to a slotted screw drive without camming it out or snapping the head off the screw. The screwdriver isn’t self-centering either, so applying force off-axis is common and contributes to the problem.

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CNC Scroll Saw Add-On Cuts Beautiful Wooden Spirals

March 25, 2021 by Dan Maloney 23 Comments

If there’s one thing that woodworkers have always been good at, it’s coming up with clever jigs and work-holding solutions. Most jigs, however, are considerably simpler and more static than this CNC-controlled scroll saw add-on that makes cool wooden spirals a snap.

As interesting as the products of this setup are, what we like about this is the obvious care and craftsmanship [rschoenm] put into making what amounts to a hybrid between a scroll saw and a lathe. Scroll saws are normally used to make narrow-kerf cuts in thin, delicate materials, often with complicated designs using very tight radius turns. In this case, though, stock is held between centers on the lathe-like carriage. The jig uses a linear slide driven by a stepper and a lead screw to translate the workpiece perpendicular to the scroll saw blade while a geared headstock rotates it. Starting with the blade inserted into a through-hole, the saw slowly cuts a beautiful nested spiral down the length of the workpiece. An Uno, a GRBL shield, and some stepper drivers let a little G-code control the two axes of the jig.

The video below shows it in action; things do get a bit wobbly as the cut progresses, but in general the jig works wonderfully and results in some lovely pieces. At first we thought these would purely be objets d’art, but then we thought about this compression screw grinder for DIY injection molding machines and realized these wooden screws look pretty similar.

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Ask Hackaday: What’s In Your Fastener Bin?

January 11, 2021 by Dan Maloney 143 Comments

A Saturday afternoon. The work week was done, the household chores were wrapped up, and with almost a week left until Christmas, there was just enough wiggle room to deny that there was still a ton of work left to prepare for that event. It seemed like the perfect time to escape into the shop and knock out a quick project, one that has been on the back burner since at least March. I’m nothing if not skilled in the ways of procrastination.

This was to be a simple project — adding an aluminum plate to a plastic enclosure that would serve as an antenna entry point into my shack. Easy as pie — cut out an rectangle of aluminum, cut and drill a few holes, call it a day. Almost all of my projects start out that way, and almost every time I forget that pretty much every one of those builds goes off the rails at exactly the same point: when I realize that I don’t have the fasteners needed. That’s what happened with this build, which had been going swimmingly up to that point — no major screw-ups, no blood drawn. And so it was off to the hardware store I trundled, looking for the right fasteners to finish the job.

Finding hardware has long been where my productivity goes to die. Even though I live a stone’s throw from at least half a dozen stores, each with a vast selection of hardware and most open weekends and nights, the loss of momentum that results from changing from build-mode to procure-mode has historically been deadly to my projects. I’m sure I’m not the only one who has run into this issue, so the question is: what can a hacker do to prevent having to run out for just the right fasteners?

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