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.
We’ve often said that one of the best applications of desktop 3D printing is the production of custom enclosures. A bespoke case adds a touch of professionalism to any project, and considering the materials needed to print one will cost less than even the cheapest generic project box, it’s a no-brainer. There’s only one problem: it can take hours to print even a simple case.
As you might expect, there are some trade-offs here. For one, the walls of the box can’t be very thick since the printer is only making one pass. The nozzle on most printers is 0.4 mm, but in his experiments, [Electrobob] has found he’s able to reliably double that to a wall thickness of 0.8 mm by adjusting the extrusion rate.
You also need to approach the design a bit differently during the CAD phase. Printing holes in the side of the enclosure, which would be easy enough to do normally, doesn’t really work when running in spiral mode. For those situations, [Electrobob] recommends designing a “pocket” into the side that you can come back and cut out with a knife. It will add a little time to the post-processing stage, but the time saved during the print will more than make up for it.
So how much faster are we talking about? In the example [Electrobob] shows in his write-up, the print time went from nearly two hours to just 18 minutes. The resulting enclosure obviously looks a bit different than the traditionally printed version, and isn’t as strong, but the concept still clearly holds promise for some applications. If you’re building a sensor network that needs a bunch of enclosures, those time savings will really add up.