wood

102 Articles

3D Printer Meets CNC Router To Make Wood Prints

July 25, 2019 by 29 Comments

We’ve seen plenty of plywood 3D printers before; after all, many early hobbyist machines were made from laser-cut plywood. But this plywood 3D-printer isn’t made from plywood – it prints plywood. Well, sort of.

Yes, we know – that’s not plywood the printer is using, but rather particleboard, the same material that fills the flatpack warehouse of every IKEA store. And calling it a printer is a bit of a stretch, too. This creation, by [Shane Whigton] and his Formlabs Hackathon team, is more of a hybrid additive-subtractive CNC machine. A gantry-mounted router carves each layer of the print from a fresh square of material – which could just as easily be plywood as particleboard. Once a layer is cut, the gantry applies glue to it, puts a fresh sheet of material on top, and clamps it down tight. The router then carves the next layer, and so on up the stack. The layer height is limited to the thickness of the material – a nominal 3/4″ (19 mm) in this case – and there’s a remarkable amount of waste, but that’s not really the point. Check out the printer in action and the resulting giant Benchy in the video below.

Seeing all that particleboard dust and glue got us thinking: what about a 3D-printer that extrudes a paste of sawdust mixed with glue? We imagine that would be a bit like those giant printers that extrude concrete to build houses.
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Project Egress: The Hinges

July 18, 2019 by 34 Comments

A door’s hinges are arguably its most important pieces. After all, a door without hinges is just, well, a wall. Or a bulkhead, if we’re talking about a hingeless hatch on a spacecraft.

And so the assignment for creating hinges for Progress Egress, the celebration of the 50th anniversary of the Apollo 11 landing by creating a replica of the command module hatch, went to [Jimmy DiResta]. The hinges were complex linkages that were designed to not only handle the 225 pound (102 kg) hatch on the launch pad, but to allow extended extravehicular activity (EVA) while en route to the Moon. [Jimmy], a multimedia maker, is just as likely to turn metal as he is to work in wood, and his hinges are a study of 1960s aerospace engineering rendered in ipe, and extremely hard and dense tropical hardwood, and brass.

[Jimmy]’s build started with a full-size 3D-printed model of the hinge, a move that paid off as the prints acted both as templates for machining the wood components and as test jigs to make sure everything would articulate properly. Sheet brass was bent and soldered into the hinge brackets, while brass rod stock was turned on the lathe to simulate the hydraulic cylinder hinge stays of the original. The dark ipe and the brass work really well together, and should go nicely with [Fran Blanche]’s walnut and brass latch on the assembled hatch.

With [Adam Savage]’s final assembly of all the parts scheduled for Thursday the 18th, we’re down to the wire on this celebration of both Apollo and the maker movement that was at least in part born from it.

Note: the assembly started at 11:00 Eastern time, and there’s a live stream at https://airandspace.si.edu/events/project-egress-build.

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JigFab Makes Woodworking Easier

April 22, 2019 by 20 Comments

Woodworking is an age-old craft that requires creativity and skill to get the best results. Experienced hands get the best results, while the new builder may struggle to confidently produce even basic pieces. JigFab is here to level the playing field somewhat.

Much of the skill in woodworking comes with mastering the various joints and techniques required to hold a piece together. Cutting these joints often requires specialized tools and equipment – ideally, some sort of jig. These jigs can be difficult to build in themselves, and that’s where JigFab shines.

The workflow is straightforward and quite modern. A piece is designed in Autodesk Fusion 360. Various joints can then be defined in the model between individual parts. JigFab then generates a series of laser cut constraints that can be used with power tools to easily and accurately cut the necessary parts to build the final piece.

It’s an impressive technology which could rapidly speed the workflow of anyone experimenting with woodwork and design. There’s even smart choices, like having a toolkit of standard predefined elements that reduce laser cutting time when producing new constraints. If you’re eager to get stuck in to woodwork, but don’t know where to start, don’t worry – we’ve got a primer for that. Video after the break.

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Printing On Wood, With An Inkjet

April 19, 2019 by 16 Comments

As a little experiment in desktop printing, because you can make a desk out of wood, [BlueFlower] modified a standard inkjet printer to print on wood. This is not an electronics mod by any means; this is still a printer that’s plugged into a USB port, does all the fancy printer firmware stuff, tells you to refill the yellow ink cartridge when you only want to print black, and all the other things that inkjet printer firmware will do. This is a mechanical mod. By taking apart the belts and rails and mounting them to a new frame, [BlueFlower] was able to open up the printer so a moving bed holding a board could be moved through the mechanics.

While the printer itself looks a little janky, you can’t argue with results. The prints look good, and should hold up well with a bit of finish. There’s a height adjustment for different thicknesses of stock, and if you’re exceptionally clever, you might be able to put a six-foot-long board through this thing. You can check out a video of this direct to wood printer in action below.

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Home-Brew CNC Router Mills A Wooden Mouse

April 15, 2019 by 19 Comments

First off, we’ll admit that there no real practical reason for wanting a wooden mouse – unless of course the cellulose rodent in question is the one that kicked it all off in “The Mother of All Demos” fifty years ago. Simply putting a shell around the guts of a standard wireless optical mouse is just flexing, but we’re OK with that.

That said, [Jim Krum]’s design shows some impressive skills, both in the design of the mouse and the build quality of his machine. Starting with what looks like a block of white oak, [Jim] hogs out the rough shape of the upper shell and then refines it with a small ball-end mill before flipping it over to carve the other side. His registration seems spot on, because everything matches up well and the shell comes out to be only a few millimeters thick. The bottom plate gets the same treatment to create the complex shape needed to support the mouse guts and a battery holder. He even milled a little battery compartment cover. He used a contrasting dark wood for the scroll wheel and a decorative band to hold the top and bottom together and finished it with a light coat of sealer.

It’s a great look, and functional too as the video below reveals. We’ve seen a few other fancy mice before, like this wood and aluminum model or even one that would look at home on [Charles Babbage]’s desk.

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Wood SCARA Arm Gets A Grip

March 14, 2019 by 4 Comments

[Ignacio]’s VIRK I is a robot arm of SCARA design with a very memorable wooden body, and its new gripper allows it to do a simple pick and place demo. Designing a robot arm is a daunting task, and the fundamental mechanical design is only part of the whole. Even if the basic framework for a SCARA arm is a solved problem, the challenge of building it and the never-ending implementation details make it a long-term project.

When we first saw VIRK I in all its shining, Australian Blackwood glory, it lacked any end effector and [Ignacio] wasn’t sure of the best way to control it. Since then, [Ignacio] has experimented with Marlin and Wangsamas support for SCARA arms, and designed a gripper based around a hobby servo. It’s as beautiful to see this project moving forward as it is to see the arm moving ping-pong balls around, embedded below.

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The Coco-Nutcracker

January 12, 2019 by 10 Comments

Coconut is a delicious and versatile food but if you’ve ever tried to open one you know they can be a hard nut to crack. Those of us who live in the tropics where they are common might reach for a machete, drill, or saw to open them, which is often a messy and sometimes dangerous ordeal. Realizing that a coconut is just a large nut with a shell like any other, [Paul] of [Jackman Works] decided to build a nutcracker big enough to crack a coconut, which turns out to be almost exactly human-sized.

The nutcracker is built almost entirely out of reclaimed wood. Several rings made of many blocks of wood were constructed on the table saw before being glued and clamped together. Once the rings were stacked and glued to each other, [Paul] put them on a lathe to get a smooth finish. Then the arms, legs, body, and head were all assembled. The actual nutcracking mechanism is one of the few metal parts in this build, a long threaded rod which is needed to handle the large forces required for cracking the coconut.

Once the finishing touches were put on the nutcracker, including boots, a beard, some hair, and of course a pom-pom for his hat, [Paul] successfully tested it by cracking a coconut open. This build is exceptionally high quality and is definitely worth scrolling through. He runs a wood shop in DC where he builds all sorts of interesting things like this, including a giant wooden utility knife.