Precision DIY Calipers? That’s A Moiré!

March 7, 2018 by Lara Grant 23 Comments

Moiré patterns are a thing of art, physics, and now tool design! [Julldozer] from Mojoptix creatively uses a moiré pattern to achieve a 0.05 mm precision goal for his custom designed 3D printed calipers. His calipers are designed to validate a 3D print against the original 3D model. When choosing which calipers are best for a job, he points out two critical features to measure them up against, accuracy and precision which he explains the definition of in his informative video. The accuracy and precision values he sets as constraints for his own design are 0.5 mm and 0.05 mm respectively.

By experimenting with different parameters of a moiré pattern: the scale of one pattern in relation to the other, the distance of the black lines on both images, and the thickness of black and white lines. [Julldozer] discovers that the latter is the best way to amplify and translate a small linear movement to a standout visual for measurement. Using a Python script which he makes available, he generates images for the moiré pattern by increasing line thickness ratios 50:50 to 95:5, black to white creating triangular moiré fringes that point to 1/100th of a millimeter. The centimeter and millimeter measurements are indicated by a traditional ruler layout.

Looking for more tool hacks and builds? Check out how to prolong the battery life of a pair of digital calipers and how to build a tiny hot wire foam cutter.

Continue reading “Precision DIY Calipers? That’s A Moiré!” →

3D Printering: Printing Sticks For A PLA Hot Glue Gun

February 5, 2018 by Donald Papp 84 Comments

When is a hot glue stick not a hot glue stick? When it’s PLA, of course! A glue gun that dispenses molten PLA instead of hot glue turned out to be a handy tool for joining 3D-printed objects together, once I had figured out how to print my own “glue” sticks out of PLA. The result is a bit like a plus-sized 3D-printing pen, but much simpler and capable of much heavier extrusion. But it wasn’t quite as simple as shoving scrap PLA into a hot glue gun and mashing the trigger; a few glitches needed to be ironed out.

Why Use a Glue Gun for PLA?

Some solutions come from no more than looking at two dissimilar things while in the right mindset, and realizing they can be mashed together. In this case I had recently segmented a large, hollow, 3D model into smaller 3D-printer-sized pieces and printed them all out, but found myself with a problem. I now had a large number of curved, thin-walled pieces that needed to be connected flush with one another. These were essentially butt joints on all sides — the weakest kind of joint — offering very little surface for gluing. On top of it all, the curved surfaces meant clamping was impractical, and any movement of the pieces while gluing would result in other pieces not lining up.

An advantage was that only the outside of my hollow model was a presentation surface; the inside could be ugly. A hot glue gun is worth considering for a job like this. The idea would be to hold two pieces with the presentation sides lined up properly with each other, then anchor the seams together by applying melted glue on the inside (non-presentation) side of the joint. Let the hot glue cool and harden, and repeat. It’s a workable process, but I felt that hot glue just wasn’t the right thing to use in this case. Hot glue can be slow to cool completely, and will always have a bit of flexibility to it. I wanted to work fast, and I wanted the joints to be hard and stiff. What I really wanted was melted PLA instead of glue, but I had no way to do it. Friction welding the 3D-printed pieces was a possibility but I doubted how maneuverable my rotary tool would be in awkward orientations. I was considering ordering a 3D-printing pen to use as a small PLA spot welder when I laid eyes on my cheap desktop glue gun.

Continue reading “3D Printering: Printing Sticks For A PLA Hot Glue Gun” →

Twitter Celebration Of Scientist Hacks For Lab And Field

February 1, 2018 by Roger Cheng 4 Comments

If you like reading about scientists creatively using household objects for their work, you will enjoy browsing Twitter hashtag #reviewforscience where scientists are sharing stories of repurposing everyday things for their lab and field.

Research papers focus on the scientific hypothesis and the results of testing it. It is very common for such papers to leave out details of tools and techniques as irrelevant. (A solid scientific conclusion should be reproducible no matter what tools and techniques are used.) This sadly meant much of scientists’ ingenuity never see light.

We can thank Amazon user [John Birch] for this event. His son wished to study how ants from different colonies interact. In order to observe how these groups of ants react to each other while still keeping the populations separate, he wanted to keep one group of ants inside a tea strainer. He posted this technique as a review on the tea strainer’s Amazon product page, where it caught the attention of @RobynJWomack and started spreading, taking off when @DaniRabaiotti suggested the tag #reviewforscience.

Sadly, it appears our original scientist (who posted under his dad’s Amazon account) did not succeed with the tea strainer technique. But he has succeeded in drawing attention to creativity in science worldwide, as well as making his dad internet famous.

We love lab hacks here. For scientists who wish there was a place to document their creative lab hacks, might we suggest Hackaday.io?

[via Washington Post]

Ancient Insect Scales Analyzed With Help Of Nose Hair

January 21, 2018 by Roger Cheng 15 Comments

Scientists working to advance the frontier of knowledge frequently also need to invent their tools along the way. Sometimes these are interesting little hacks to get a job done. Recently some researchers found ancestors of moths and butterflies older than any previously known by analyzing tiny scales found alongside ancient pollen. They needed a tool to manipulate these scales: separating them from surrounding debris, transferring them to microscope slides. The special tool was a needle tipped with a single human nostril hair.

As ancient insects were the published paper‘s focus, their use of nose hair tipped needle was only given a brief mention in the “Materials and Methods” section. Interviews by press quoted researchers’ claim that nose hair has the right mechanical properties for the job, without further details. Not even a picture of the tool itself. What properties of insect scales made them a good match with the properties of nose hair? Was there a comprehensive evaluation of multiple types of hair for the task? Would we regret asking these questions?

Novel approaches to fine-tipped tools would be interesting to examine under other contexts, like the tweezers we use to build surface-mount electronics. As SMD parts continue to shrink in size, will we reach a point where hair-tipped tools are the best DIY alternative to an expensive pick-and-place machine? It would be another creative approach to deal with the challenges of hand-built SMD. From simple but effective mechanical helpers, to handy 3D printed tools, to building hybrid Manual + CNC pick-and-place more affordable than their fully automated counterparts.

[via Washington Post]

Digital Kiln

December 16, 2017 by Brian McEvoy 31 Comments

A kiln or foundry is too often seen as a piece of equipment which is only available if a hackspace is lucky enough to have one or individuals are dedicated enough to drop the cash for one of their own. [The Thought Emporium] thought that way until he sourced materials to make his own kiln which can also be seen after the break. It costs half the price of a commercial model not including a failed—and exploded—paint can version.

As described in the video, these furnaces are tools capable of more than just pottery and soft metal baubles. Sure, a clay chess set would be cool but what about carbon fiber, graphene, aerogel, and glass? Some pretty hot science happens at high temperatures.

We get a nice walk-through of each part of the furnace starting with the container, an eleven-gallon metal tub which should set the bar for the level of kiln being built. Some of the hardware arrangements could be tweaked for safety and we insist that any current-carrying screw is safely mounted inside an enclosure which can’t be opened without tools. There’s good advice about grounding the container if metal is used. The explanation of PID loops can be ignored.

What else can you do with a kiln? How about jewelry, heat treating metal, or recycle your beer cans into an engine.

Continue reading “Digital Kiln” →

Shop-Made Fixture Turns Out Dream Welds

November 10, 2017 by Dan Maloney 14 Comments

You can tell a lot about a person by the company they keep, and you can tell a lot about a craftsman by the tools and jigs he or she builds. Whether for one-off jobs or long-term use, these ad hoc tools, like this tubing rotator for a welding shop, help deliver results beyond the ordinary.

What we appreciate about [Delrin]’s tool is not how complex it is — with just a motor from an old satellite dish and a couple of scooter wheels, it’s anything but complicated. What we like is that to fabricate some steering links, each of which required three passes of TIG welding to attach a threaded bung to the end of a rod, [Delrin] took the time to build just the tool for the job. The tools slowly rotates the rod, letting the welder keep the torch in one position as the workpiece moves under it. The grounding method is also simple but clever — just a wide strap of braid draped over the rod. The result is some of the prettiest and most consistent welds we’ve seen in a while, and with an order for 28 steering links, it ought to be a huge time saver.

It may be time for a little more TIG welding love around here. Sure, we’ve covered the basics of oxy-acetylene welding, and even talked about brazing aluminum. Perhaps your humble Hackaday writer will take the plunge into a new TIG welder and report from a newbie’s perspective. You know, for science.

[via r/welding]

The Most Useless Tools You Can’t Seem To Part With

October 26, 2017 by John Baichtal 180 Comments

I’m a tool person. No matter how hard I try, I eventually end up with a bunch of tools that I just can’t bear to banish from my workshop. Why? I’m gonna keep it 100%: it’s the same emotion behind hoarding — fearing that you might need a thing later and not be able to have it.

The stuff costs money, and if you have to script to buy a bunch of tools pertaining to Project X, you expect to still have and probably need those very same tools — even if they have to sit in a box on my shelf for 20 years, taunting me every time I have to move it to one side. “Heat-bending element” the box’s label describes at tool I haven’t used in at least 5 years. I have a bunch of these white elephants. I’ll probably need to heat-bend acrylic real soon… yeah.

I’ve found that pretty much everyone in our crowd can relate. You buy a special tool for one project and it was expensive and tremendously helpful, and since then it’s been sitting around uselessly. You certainly couldn’t part with it, what if you needed it again? So you store it in your house for 20 years, occasionally coming across it when looking for something else, but it never actually gets used.

Join me now in a walk down our memory lane of useless tools.

Continue reading “The Most Useless Tools You Can’t Seem To Part With” →