Category Archives: casting

Printable, Castable Feeders Simplify Pick-and-Place Component Management

It goes without saying that we love to see all the clever ways people have come up with to populate their printed circuit boards, especially the automated solutions. The idea of manually picking and placing nearly-microscopic components is reason enough to add a pick and place to the shop, but …read more

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Posted in casting, cnc hacks, feeder, LitePlacer, pawl, pick and place, pnp, resin, smd, sprocket, tape | Leave a comment

Cheap Strain Relief By Casting Hot Glue in a 3D Print

[Daniel Roibert] found a way to add cheap strain relief to JST-XH connectors, better known to hobby aircraft folks as the charging and balance connectors on lithium-polymer battery packs. His solution is to cast them in hot glue, with the help of 3D printed molds. His project provides molds fitted …read more

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Posted in 3d printed, 3d Printer hacks, battery, casting, drone hacks, hot glue, how-to, JST, jst-xh, lipo, mold, rc, strain relief | Leave a comment

Watch a Sand-Cast Slingshot Made, From Start To Finish

Sand-casting metal parts is a technique that has been around for a very long time, but it can be educational to see the process from start to finish. That’s exactly what [Frederico] shows us with his sand-cast slingshot of his own design, and it’s not bad for what he says …read more

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Posted in aluminum, casting, classic hacks, mold, sand casting, slingshot | Leave a comment

Retrotechtacular: The Art of the Foundry

Mention the term “heavy industry” and the first thing to come to mind might well be the metal foundry. With immense machines and cauldrons of molten metal being shuttled about by crane and rail, the image of the foundry is like a scene from Dante’s Inferno, with fumes filling …read more

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Posted in Boiler, cast iron, casting, fettling, fitting, foundry, Hackaday Columns, Retrotechtacular, steam, steel | Leave a comment

Casting Gears At Home

Automatic doors and gates are great, except when they fail, which seems to be about every three days in our experience. [MAD WHEEL] had just such a failure, with a plastic gear being the culprit. Rather than buy a new drive unit, they set about casting a replacement in metal. …read more

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Posted in aluminium casting, cast gear, casting, gear, tool hacks | Leave a comment

Scrapyard Milling Machine Gets Work Done on a Budget

Which to buy first, a lathe or a mill? It’s a tough question for the aspiring home machinist with limited funds to spend on machine tools, but of course the correct answer is a lathe. With a lathe, we are told, all other machine tools can be built, including a …read more

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Posted in casting, compound, cross feed, lathe, metalwork, mill, milling machine, spindle, taper, tool hacks | Leave a comment

Casting CNC Parts In Aluminium

When it comes to machining, particularly in metal, rigidity is everything. [Tailortech] had a homebuilt CNC machine with a spindle held in place by a plastic bracket. This just wasn’t up to the job, so the decision was made to cast a replacement.

[Tailortech] decided to use the lost PLA …read more

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Posted in aluminium casting, casting, cnc, lost pla casting, tool hacks | Leave a comment

A No-Cost, Heavy Metal Lathe From Junkyard Parts

We have to admit that our first thought on seeing a Frankenlathe made from old engine blocks was that it was a set piece from a movie like The Road Warrior. And when you think about it, the ability to cobble together such a machine tool would probably make …read more

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Posted in cast iron, casting, engine block, gingery, junkyard, lathe, Machine tool, tool hacks | Leave a comment

Cloning Knobs For Vintage Testing Equipment

Knobs! Shiny candy-colored knobs! The last stand of skeuomorphism is smart light switches! Everyone loves knobs, but when you’re dealing with vintage equipment with a missing knob, the odds of replacing it are slim to none. That’s what happened to [Wesley Treat] when he picked up a vintage Philco tube tester. The tester looked great, but a single knob for a rotary switch was missing. What to do? Clone some knobs! You only need some resin and a little bit of silicone.

The process of copying little bits of plastic or bakelite is fairly standard and well-tread territory. Go to …read more

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Posted in casting, cloning knobs, knob, misc hacks, Philco, resin, silicone | Leave a comment

Fail of the Week: When Good Foundries Go Bad

Like many of us, [Tony] was entranced by the idea of casting metal, and set about building the tools he’d need to melt aluminum for lost-PLA casting. Little did he know that he was about to exceed the limits of his system and melt a hole in his patio.

[Tony]’s tale of woe begins innocently enough, and where it usually begins for wannabe metal casters: with [The King of Random]’s homemade foundry-in-a-bucket. It’s just a steel pail with a homebrew refractory lining poured in place, with a hole near the bottom to act as a nozzle for forced air, or  …read more

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Posted in casting, charcoal, coal, Fail of the Week, forge, foundry, furnace, kiln, lost PLA | Leave a comment