Category Archives: casting

Junkyard Crossbow Aims to be a Car Killer

[James], aka [Turbo Conquering Mega Eagle], is not your typical Hackaday poster boy. Most of his builds have a  “Junkyard Wars” vibe, and he’d clearly be a good man to have around in a zombie apocalypse. Especially if the undead start driving tanks around, for which purpose his current anti-tank compound crossbow is apparently being developed.

At its present prototype phase, [James]’ weapon o’ doom looks more fearsome than it actually is. But that’s OK — we’re all about iterative development here. Using leaf springs from a Toyota Hi-Lux truck, this crossbow can store a lot of energy, which is …read more

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Posted in casting, composite, compound bow, crossbow, laminated, spring, trigger, weapons hacks | Leave a comment

The Fine Art of Heating And Cooling Your Beans

They say that if something is worth doing, it’s worth doing right. Those are good words to live by, but here at Hackaday we occasionally like to adhere to a slight variation of that saying: “If it’s worth doing, it’s worth overdoing”. So when we saw the incredible amount of work and careful research [Rob Linnaeus] was doing just to roast coffee beans, we knew he was onto something.

The heart of his coffee roaster is a vortex chamber with an opening on the side for a standard heat gun, and an aperture in the top where an eight cup …read more

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Posted in 3D printed mold, 3d Printer hacks, casting, coffee, cooking hacks, refractory cement | Leave a comment

Enresoning An iPhone 8 Ring

The iPhone 8 was just released last week, and that means some people were standing in line in front of an Apple store for hours waiting to get their hands on the latest and greatest glowing rectangle. [Patrick Adair] had a better idea: he would stand in front of an Apple store for four hours, then do something productive with his new smartphone. With the help of a waterjet, some resin, a lathe, and some very fine grades of sandpaper, he created the Apple Ring.

Setting aside the whole process of actually acquiring an iPhone 8 on launch day, the …read more

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Posted in casting, lathe, misc hacks, resin, turning, waterjet | Leave a comment

Harvesting Copper from Microwave Ovens

Obsolete appliances were once a gold mine of parts, free for the taking with a few snips of your diagonal cutters. Times have changed, though, and most devices yield only a paltry supply of parts, so much so that only by harvesting raw materials can you get much value out of them. And so we have this example of reclaiming copper from used microwave ovens.

The primary source of copper in most microwaves is the transformer, which we usually see re-tasked for everything from spot welders to material handling electromagnets. But the transformer is not the only source of the …read more

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Posted in casting, coil, copper, e-waste, foundry, green hacks, microwave oven transformer, misc hacks | Leave a comment

A Great Way to Make Quick and Easy Knobs

Here’s a great way to quickly and easily make attractive and functional knobs with no tools required. All you need is some casting resin (epoxy would do in a pinch), a silicone mold intended for candy, and some socket head bolts. With the right preparation and a bit of careful placement and attention, smooth and functional knob ends are only minutes away. Embedded below is a short video demonstrating the process.

These may not replace purpose-made knobs for final products, but for prototypes or to use around the shop on jigs, clamps, or furniture they certainly fit the bill. With …read more

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Posted in bolt, casting, diy, epoxy, how-to, knobs, mold, resin, silicone, socket head bolt, threaded knob, tool hacks, tool-free | Leave a comment

Silicone Molds for Stove-Top Metal Casting

Casting metal parts from 3D-printed plastic or Styrofoam models is all the rage these days, and for good reason — casting is a way to turn one-offs into mass-produced parts. Seems like most of the metal casting projects we feature are aluminum in sand molds, though, so it’s refreshing to see a casting project using silicone molds to cast low-melting point metals.

Don’t get us wrong — sand-cast aluminum is a great method that can even be used to build a lathe from scratch. But not everyone wants to build a foundry and learn the sometimes fussy craft of creating …read more

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Posted in bismuth-tin, casting, foundry, LMP, low melting point, misc hacks, mold, silicone | Leave a comment

The Tuna Fish Sandwich Foundry

Can you build a foundry out of a loaf of bread and a can of tuna fish? As it turns out, yes you can. And not only can you melt aluminum in said foundry but you can also make a mold from plain beach sand and cast a usable part.

Through the magic of backwoods engineering and that can-do Canadian attitude, [AvE] demonstrates in his inimitable style how a pyrolized loaf of sourdough bread can serve as a perfectly acceptable foundry, using a tuna can as a crucible. We covered [AvE]’s carbon foam creation process before and showed some of …read more

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Posted in aluminum, carbon foam, casting, choocher, foundry, lost foam, misc hacks, pyrolysis, skookum | Leave a comment

Gateway to Metal Casting

Casting is an exciting and very useful pastime, but it’s not exactly common these days. That’s a problem whether you’re just getting started or have been doing it for years: everyone can use the advice of another. Fear not! The US Department of Energy is here to help with the Industrial Metal’s Program’s Metal Casting cornucopia.

Although not strictly a hack, this is certainly a facilitator of hacks and any experienced user would do themselves some good by perusing the site. Click on the maps to find complex issues presented remarkably well for papers at this level of rigor. Seriously, …read more

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Posted in casting, Educational, how-to, metal, metal casting | Leave a comment

Foundry From Scrapped Oven for Cheap, Clean Castings

Home-built foundries are a popular project, and with good reason. Being able to melt and cast metal is a powerful tool, even if it’s “only” aluminum. But the standard fossil-fuel fired foundries that most people build are not without their problems, which is where this quick and clean single-use foundry comes into play.

The typical home foundry for aluminum is basically a refractory container of some kind that can take the heat of a forced-air charcoal or coal fire. But as [Turbo Conquering Mega Eagle] points out, such fuels can lead to carbon contamination of the molten aluminum and imperfections …read more

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Posted in aluminum, casting, electric, foundry, misc hacks, oven, range, stove, tool hacks | Leave a comment

Tools of the Trade – Injection Molding

Having finished the Tools of the Trade series on circuit board assembly, let’s look at some of the common methods for doing enclosures. First, and possibly the most common, is injection molding. This is the process of taking hot plastic, squirting it through a small hole and into a cavity, letting it cool, and then removing the hardened plastic formed in the shape of the cavity.

The machine itself has three major parts; the hopper, the screw, and the mold. The hopper is where the plastic pellets are dumped in. These pellets are tiny flecks of plastic, and if the …read more

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Posted in casting, Curated, custom enclosure, enclosure design, enclosures, Engineering, Featured, injection mold, injection molding | Leave a comment