A 3D Printed Ratchet That Can Really Take The Torque

October 15, 2022 by Donald Papp 5 Comments

Printed tools aren’t exactly known for their durability, but [Gladius] shows us that with some thoughtful design, it’s possible to print a ratcheting wrench that can handle surprising amounts of torque.

Look closely, and you can see that the parts are almost entirely made up of perimeters (click to enlarge).

This particular wrench is inspired by NASA’s 3D printed ratcheting wrench, and also from an early 1900s design. It sports a 1/2 inch square socket into which modern adapters can be fitted, allowing those steel parts to do their job while the wrench itself delivers the muscle.

[Gladius] found that the strongest results came from slicing parts — especially the handle — so that they come out consisting almost entirely of perimeters, with virtually no traditional infill. Want to know more? There’s a discussion on reddit where [Gladius] goes into added detail about measurements and performance.

Over the years, we’ve seen our share of powerful prints. For example, what the Crimson Axlef*cker can do looks downright intimidating. Speaking of printing things that move, we want to remind you about this handy tip for easily and reliably joining motor shafts to printed parts by (mis)using jaw couplings.

Printed Axial Generator Is Turned By Hand

October 15, 2022 by Bryan Cockfield 19 Comments

While desktop 3D printing is an incredible technology, it’s got some pretty clear limitations. Plastic parts can be produced quickly in a 3D printer but can be more expensive or take longer to make than parts from materials like wood. Plastic parts can also be weaker than materials like metal. If a 3D printer is all you have on hand, though, you can often make some design choices that improve the performance of a plastic part over other materials. That’s what [1970sWizard] did to make this axial hand-cranked generator.

Besides a few pieces of off-the-shelf hardware and the wire and magnets, the entire generator is printed. The actual generator is made from coils of wire with exposed leads which snap into a plastic disc which acts as the generator’s stator. The magnets also snap into a separate disc which is the rotor of the generator and is attached to the drivetrain, with no glue or fasteners required. A series of gears on two other axes convert the torque from the hand crank into the high speed necessary to get usable electricity out of the generator.

The separate gear shafts were necessary to keep from needing a drillpress, which would have allowed fewer axes to be used. This entire machine can be built almost entirely with a desktop 3D printer, though, which was one of the design goals. While it’s largely a proof-of-concept, the machine does generate about 100 mW of power which is enough to slowly charge USB devices, power lights, or provide other sources of very small amounts of energy. If you do have access to some metalworking tools, though, take a look at this hand-cranked emergency generator.

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Peer-Reviewed Continuity Tester

September 30, 2022 by Bryan Cockfield 10 Comments

One of the core features of the scientific community is the concept of “peer review” where any claims made by a scientist are open to be analyzed and reproduced by others in the community for independent verification. This leads to either rejection of ideas which can’t be reproduced, or strengthening of those ideas when they are. In this community we typically only feature the first step of this process, the original projects from various builders, but we don’t often see someone taking those instructions and “peer reviewing” someone’s build. This is one of those rare cases.

[oxullo] came across [Leo]’s original build for the ultimate continuity tester. This design is much more sensitive than the function which is built in to most multi-meters, and when building this tool specifically some other refinements can be built in as well. [oxullo] began by starting with the original designs, but made several small modifications. Most of these were changing to surface-mount parts, and switching some components for ones already available. Even then, there was still a mistake in the PCB which was eventually corrected. The case for this build is also 3D printed instead of being made out of metal, and with the original video to work from the rest fell into place easily.

[oxullo] is getting comparable results with this continuity tester, so we can officially say that this design is peer reviewed and tested to the highest of standards. If you’re in need of a more sensitive continuity sensor, or just don’t want to shell out for a Fluke meter when you don’t need the rest of its capabilities, this is the way to go. And don’t forget to check out our original write-up for this tester if you missed it the first time around.

Printable One-Way Driver Skips Ratchet For A Clutch

August 25, 2022 by Lewin Day 6 Comments

Ratcheting screwdrivers can help you work faster, even if their bulk means they’re not the best option for working in tight spaces. [ukman] decided to build a similar device of his own, relying on a slightly different mechanism — an overrunning clutch.

The design is similar to a freewheel used on a bicycle, allowing free movement in one direction while resisting it in the other. As the screwdriver is turned in one direction, the shaft is wedged by a series of cylinders that lock it in place. However, the geometric shape of the clutch allows the shaft to turn in the other direction without getting wedged in place. The result is a screwdriver that can be turned, rolled back, and turned further. Thus, screws can be tightened without loosening one’s grip on the tool.

With its 3D printed construction, it’s probably not the best tool for heavy-duty, high-torque jobs, but it looks more than capable of handling simple assembly tasks. We’ve seen some other nifty screwdrivers around these parts, too.

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Angled Drill Guide Helps You With Those Tricky Holes

August 18, 2022 by Lewin Day 18 Comments

If you’ve ever tried to drill a hole on an angle with a power drill, you’ve probably drilled some pretty shocking holes. To do it right, you really need some mechanical assistance, and this jig from [Kartik_Nandrui] should do the trick.

The device uses a guide that sits on the surface to be drilled, with a pair of angled connectors that fit two wooden dowels. These connect the guide to a corresponding sleeve that fits around the drill body. The sleeve then slides up and down the dowels, allowing the drill to move in a straight line towards the targeted area.

It’s a useful hack, but we can see room for some improvements that would take it to the next level. Having a way to lock the angle of the guide base would be great for accuracy. As it’s 3D printed, it would also be simple to create a version with a curved guide base that could fit over pipes, or other designs to fit complex geometries like roof sheeting or other corrugated materials.

Sometimes the most interesting hacks are the ones that get us thinking about our own potential projects. If you’ve got any creative tool hacks you’ve been brewing up in the lab, be sure to let us know!

Testing A Laser Cut Wrench VS A Forged Wrench

August 13, 2022 by Al Williams 30 Comments

It is easy to not think much about common tools like screwdrivers and wrenches. But not for [Torque Test Channel]. The channel does a lot of testing of tools and in the video, below, they test a new wrench that is, oddly enough, laser cut instead of forged like the usual wrench.

You would expect a machined wrench to be weaker than a forged wrench. We were impressed, though, that there is so much difference between wrenches when you start making measurements.

Speaking of measurements, we would like to see more details of the test setups shown both in the video and in some of the video clips included. We did enjoy seeing the examination of the internal grain structure of both wrenches.

Be forewarned. Watching this video is likely going to send you to the computer to buy some new wrenches, especially if you don’t have 30/60 head wrenches.

The real question is why laser cut a wrench? It doesn’t seem like it is actually better than the forged variant. It is more expensive, but the setup costs for forging are higher. Particularly for a tool made in the United States, forging is both expensive and it is difficult to find time on the limited number of large-scale forges left in the country.

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Resulting tweezer assembly, with a 3D printed replacement case for both of the probes

Hackaday Prize 2022: Glue-Hindered Smart Tweezer Repair Involves A Rebuild

May 23, 2022 by Arya Voronova 1 Comment

[Dan Julio] owns a pair of Miniware multimeter tweezers, a nifty helper tool for all things SMD exploration. One day, he found them broken – unable to recognize any component between the two probes. He thought it could be a broken connection problem, and decided to take them apart. Presence of some screws on their case fooled him – in the end, it turned out that the case was glued together, and could only be opened destructively. For an entry in the “Reuse, Recycle, Revamp” round of 2022 Hackaday Prize, he tells us how he brought these tweezers back from the dead.

During the disassembly, he broke a custom flexible PCB, which wasn’t reassuring either. However, that was no reason to give up – he reverse-engineered the connections and the charging circuitry, then assembled parts of the broken tweezers together using a small generic protoboard as a base. Indeed, it was likely a broken connection between probes, because the reassembled tweezers worked!

Of course, having exposed PCBs wouldn’t do, and from the very start, assembling these tweezers back together was not an option. Instead, he developed a replacement case in OpenSCAD, bringing the tweezers back to life as his trusty tool – and still leaving repairability on the table. If you’re interested in the details, he goes more into how these tweezers are designed when it comes to charging and connectivity, and we recommend that you give his write-up a read!

We’ve been seeing smart tweezers around for over a decade now, from reviews and hacks of commercially made ones, to DIY chopstick-based and PCB-based ones. If you already own a pair of tweezers you’ve grown attached to, you can neatly retrofit them with a capacitance sensing function!