Hackaday is primarily a place for electronics hackers, but that’s not to say that we don’t see a fair number of projects where woodworking plays a key role. Magic mirror builds come to mind, as do restorations of antique radios, arcade machines built into coffee tables, and small cases for all manner of electronic and mechanical gadgets. In some of these projects, the woodworking really shines and makes the finished project pop. In others — well, let’s just say that some woodwork looks good from far, but is far from good.
Some time back, we posted about [Gavin]’s laser-cut/3D printed Dymaxion Globe — if you haven’t read about it yet, you should check it out. [noniq] loved the idea, and like a true hacker, built and shared an improved Foldable Dymaxion Globe. It can snap together to form an icosahedron globe, or it can be laid flat to form a map.
Like the original, [noniq]’s version is laser cut and engraved, and uses some 3D printed parts. But it does away with the fasteners (that’s 60 pairs of nuts and bolts), and instead uses neodymium magnets to make all the triangle pieces snap together to form the icosahedron globe. The hinges are simply some pieces of gaffer-tape.
This design improvement creates a cleaner globe and also addresses some of the concerns posted in the comments of the earlier build. The design files are available for download on [noniq]’s blog — you need to 3D print some magnet holders and stopper plates, and laser cut the 20 triangle tiles. The stopper plates help ensure that the angle between tiles when it is put together is limited to 138 degrees, making it easier to assemble the globe.
Check out the video after the break to hear the satisfying “thunk” of neodymium magnets snapping together.
Everyone knows that globes are cool — what else would you use as the centerpiece of your library/study? But, sadly, making your own isn’t a simple process. Even if you had a large (preferably hollow) sphere to work with, you’d still have to devise a clever way of printing the map in sections that can be glued to the curved surface. Wouldn’t it be easier if you could just laser cut flat sections, and assemble them to form a faceted “globe?”
Well, it is, and you can! Because, [Gavin] over at tinkerings.org (a Hackaday favorite) has created the files to do just that! This map projection, originally designed by the very interesting Buckminster Fuller, is designed to be either laid flat or three-dimensionally on an icosahedron (a 20-sided polyhedron). That makes it perfect for laser cutting, as each of the 20 faces can be cut from flat stock.
In what might be one of the coolest applications of laser cutting, joinery, puzzles, writing, and bookbinding, [Brady Whitney] has created the Codex Silenda — a literal puzzle book of magnificent proportions.
[Whitney] had originally conceived the idea of the Codex for his senior thesis research project at Iowa State University, and the result is something for almost everyone. On each of the Codex’s five pages lies a mechanical puzzle that must be solved to progress to the next, while an accompanying text weaves a story as you do so. These intricate pages were designed in SolidWorks and painstakingly assembled from laser cut wood. Breaking the fourth wall of storytelling by engaging the reader directly in uncovering the book’s mysteries is a unique feat, and it looks gorgeous to boot.
Hanging plotters, or two steppers controlling a dangling Sharpie marker on an XY plane, are nothing new to our community. But have you ever thought of trading out the Sharpie for a wood router bit and cutting through reasonably thick plywood sheets? That would give you a CNC machine capable of cutting out wood in essentially whatever dimensions you’d like, at reasonably low-cost. And that’s the idea behind [Bar]’s Maslow. It’s going to be a commercial product (we hope!), but it’s also entirely open source and indubitably DIYable.
[Bar] walks us through all of the design decisions in this video, which is a must-watch if you’re planning on building one of these yourself. Basically, [Bar] starts out like any of us would: waaaay over-engineering the thing. He starts out with a counterweight consisting of many bricks, heavy-duty roller chain, and the requisite ultra-beefy motors to haul that all around. At some point, he realized that there was actually very little sideways force placed on a sharp router bit turning very quickly. This freed up a lot of the design.
His current design only uses two bricks for counterweights, uses lighter chains, and seems to get the job done. There’s a bit of wobble in the pendulum, which he admits that he’s adjusted for in software. Motors with built-in encoders and gearing take care of positioning accurately. We haven’t dug deeply enough to see if there’s a mechanism to control the router’s plunge, which would be great to cut non-continuous lines, but first things first.
Taking the wall plotter into the woodshop is a brilliant idea, but we’re sure that there’s 99% perspiration in this design too. Thanks [Bar] for making it open! Best of luck with the Kickstarter. And thanks to [Darren] for the tip.
Woodworking is the fine art of building jigs. Even though we have Internet-connected toasters, thermostats, cars, and coffee makers, the Internet of Things hasn’t really appeared in the woodshop quite yet. That’s changing, though, and [Ben Brandt]’s Internet of Things box joint jig shows off exactly what cheap computers with a connection to the Internet can do. He’s fully automated the process of making box joints, all with the help of a stepper motor and a Raspberry Pi.
[Ben]’s electronic box joint jig is heavily inspired by [Matthias Wandel]’s fantastic screw advance box joint jig. [Matthias]’ build, which has become one of the ‘must build’ jigs in the modern woodshop, uses wooden gears to advance the carriage and stock across the kerf of a saw blade. It works fantastically, but to use this manual version correctly, you need to do a bit of math before hand, and in the worst-case scenario, cut another gear on the bandsaw.
[Ben]’s electronic box joint jig doesn’t use gears to move a piece of stock along a threaded rod. Stepper motors are cheap, after all, and with a Raspberry Pi, a stepper motor driver, a couple of limit switches, and a few LEDs, [Ben] built an Internet-enabled box joint jig that’s able to create perfect joints.
The build uses a Raspberry Pi 3 and Windows IoT Core to serve up a web page where different box joint profiles are stored. By lining the workpiece up with the blade and pressing start, this electronic box joint jig automatically advances the carriage to the next required cut. All [Ben] needs to do is watch the red and green LEDs and push the sled back and forth.
You can check out [Ben]’s video below. Thanks [Michael] for the tip.
[John Heisz] was contemplating the secrets of the universe when an errant thought led him to wonder, could I use a sheet of paper as the blade in my table saw?
He takes a sheet of regular printer paper, draws a circle on it the same diameter as his regular blades, and cuts it out. He then bolts it into place on the spindle, slots in the table saw insert for really really thin kerf blades, and fires it up.
The blade is surprisingly dangerous. One would maybe expect a paper blade to be minimally damaging to a finger at best, but it quickly shows itself to be capable of tearing through paper and cutting through wood at a reasonable clip. Since the paper is minimally conductive, a SawStop couldn’t save someone from a lack of caution.
The blade finally meets its match half way through a half-inch thick piece of wood scrap. Wood and paper dust explode outward as the experiment ends. Video after the break.