Category Archives: fabrication

Jubilee: A Toolchanging Homage to 3D Printer Hackers Everywhere

I admit that I’m late to the 3D printing game. While I just picked up my first printer in 2018, the rest of us have been oozing out beautiful prints for over a decade. And in that time we’ve seen many people reimagine the hardware for mischief besides just printing …read more

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Posted in 3d printer, 3d Printer hacks, cnc hacks, Curated, Engineering, fabricatability, fabrication, Featured, jubilee, multimaterial, toolchanger, toolchanging | Leave a comment

A Simpler Method to Make Optical Fiber with 3D Printing

There are a lot of remarkable uses for optical fiber, chief among them being telecommunications and imaging. While fiber can be produced for a better price than copper wire equivalents, they’re still not easy or cheap to manufacture.

Silica fibers require spinning tubes on a lathe, which requires the fiber’s …read more

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Posted in 3d Printer hacks, fabrication, manufacturing, Optical fiber, preform | Leave a comment

How To Make an Electric Scooter Chain Sprocket With Nothing But Hand Tools

Sometimes, mechanical parts can be supremely expensive, or totally unavailable. In those cases, there’s just one option — make it yourself. It was this very situation in which I found myself. My electric scooter had been ever so slightly bested by a faster competitor, and I needed redemption. A gearing …read more

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Posted in chain drive, chain sprocket, fabrication, Hackaday Columns, machining, scooter, scooter hacking, sprocket, sprockets, transportation hacks | Leave a comment

Replacing the 3D Printer and Router: A Tool for Manufacturing Human-Scale Forms

The purpose of Geometer becomes apparent when you realize its simplicity: [David Troetschel]’s project is to create an easily understandable design tool that encourages goal-oriented design. The kit comes with physical components and digital counterparts that can be combined in a modular way. They each have a specific geometry, which …read more

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Posted in 2019 Hackaday Prize, 3d Printer hacks, fabrication, Hackaday Prize, manufacturing | Leave a comment

WOPR: Building Hardware Worth Sharing

It wouldn’t be much of a stretch to assume that anyone reading Hackaday regularly has at least progressed to the point where they can connect an LED to a microcontroller and get it to blink without setting anything on fire. We won’t even chastise you for not doing it with …read more

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Posted in 3D printed enclosure, cons, design, fabrication, Hackaday Columns, hardware, hardware design, production, WOPR Summit | Leave a comment

Threading 3D Printed Parts: How to Use Heat-Set Inserts

We can make our 3D-printed parts even more capable when we start mixing them with some essential “mechanical vitamins.” By combining prints with screws, nuts, fasteners, and pins, we get a rich ecosystem for mechanism-making with capabilities beyond what we could simply print alone.

Today I’d like to share some …read more

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Posted in 3d Printer hacks, 3d printing, Engineering, fabrication, Featured, functional 3d printing, heat set inserts, Skills, threaded insert | Leave a comment

Oreo Construction: Hiding Your Components Inside The PCB

In recent months, the ability to hide components inside a circuit board has become an item of interest. We could trace this to the burgeoning badgelife movement, where engineers create beautiful works of electronic art. We can also attribute this interest to Bloomberg’s Big Hack, where Jordan Robertson and Michael Riley asserted Apple was the target of Chinese spying using components embedded inside a motherboard. The Big Hack story had legs, but so far no evidence of this hack’s existence has come to light, and the companies and governments involved have all issued denials that anything like this exists. …read more

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Posted in embedded components, Engineering, fabrication, Featured, guitar pedal, oreo construction, RangeBlaster, Rangemaster, stackup | Leave a comment

Hackaday Superconference: Estefannie’s Daft Punk Helmet

There’s no single formula for success, but if we’ve learned anything over the years of covering cons, contests, and hackathons, it’s that, just like in geology, pressure can create diamonds. Give yourself an impossible deadline with high stakes, and chances are good that something interesting will result. That’s what Estefannie from the YouTube channel “Estefannie Explains It All” did when Bay Area Maker Faire was rolling around last year, and she stopped by the 2018 Hackaday Superconference to talk about the interactive Daft Punk helmet that came out of it.

It’s a rapid-fire tour of Estefannie’s remarkably polished replica of …read more

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Posted in 2018 Hackaday Superconference, cons, daft punk, DragonBoard, fabrication, helmet, led hacks, mold, Skills, thermoforming, vacuum forming, wearable hacks, Wearables | Leave a comment

The Art of Vacuum Tube Fabrication

Vacuum tubes fueled a technological revolution. They made the amplification of signals a reality for transatlantic telephone cables (and transcontinental ones too), they performed logic for early computers, and they delivered that warm fuzzy sound for high fidelity audio. But they were labor intensive to produce, and fragile, so semiconductors came along and replaced tubes in almost every application. But of course tubes are still with us and some tube applications are still critical — you’ll find them used in high-power RF and there are even satellites that depend on klystrons. So there are still experts in tube fabrication around, …read more

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Posted in 2018 Hackaday Superconference, classic hacks, cons, fabrication, Hackaday Columns, tubes, vacuum tubes | Leave a comment

Homemade Shop Vise Packs a Hydraulic Punch

It’s a sad day when one of the simplest and generally most reliable tools in the shop – the bench vise – gives up the ghost. With just a pair of beefy castings and a heavy Acme screw, there’s very little to go wrong with a vise, but when it happens, why not take it as an opportunity to make your own? And, why not eschew the screw and go hydraulic instead?

That’s the path [Darek] plotted when his somewhat abused vise reached end-of-life with an apparently catastrophic casting failure. His replacement is completely fabricated from steel bar and channel …read more

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Posted in fabrication, hydraulics, metalworking, tool hacks, vise, welding, work holding | Leave a comment