Category Archives: CNC

555 Footstool for Sparky

Sparky the Blue Smoke Monster on 555

Adafruit just got a new chip for Sparky the Blue Smoke Monster! It turns out that our 555 Footstool is just the perfect size for the Sparky puppet they had made.

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As before, we cut the parts out on the CNC router from our original design.

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The parts were glued together and sanded.

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After assembly was lasering to mark and etch the notch, which we carved and chiseled to make it deeper than our previous one.

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The first layer of paint was primer grey, followed by black and silver. Once the body of the chip had a beautiful matte black finish, it went back into the laser for the manufacturer’s mark before a final protective coat of paint.

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It posed for a few pictures before heading off to meet Sparky, and we’ve posted them on flickr.

Sparky graphic side-by-side with IRL Sparky and chip

The original Sparky design side-by-side with the plush puppet and its new chip.

GeekDad on the EggBot

EggBot on workbench with daughter at computer

Mark has posted a nice writeup at GeekDad about receiving an EggBot as a birthday present:

It was the perfect gift for a GeekDad–something I wasn’t expecting and might not have bought for myself, but is so much fun that I wish I’d bought one years ago.

30 valentine ping pong balls

He used it for his daughter’s preschool:

In almost no time, I had a box of 30 Valentine’s ping pong balls for her to take to school. Her teachers were fascinated when they saw them and I was told had been debating whether we had somehow hand-drawn them all. The head teacher asked my daughter how we made them and she naturally replied: “No, a robot drew them!”

DIY Snowflake Chocolate Molds with the Othermill

Our friends at Other Machine Co. have put out a mold making kit for the Othermill and posted an instructable for making snowflake chocolates using the online Snowflake Generator that Paul Kaplan of Inventables ported from our Vector Snowflake Application.

The process involves milling a wax positive for making a silicone mold. The beautiful two-tone chocolates are made by putting white couverture chocolate into the details of the mold, and then filling the rest of the mold with dark.

One more technique we could have used for Operation: CNC Snowflake!

Introducing WaterColorBot 2.0

WaterColorBot 2.0

We are very pleased to introduce something that we’ve been working on for most of this year: WaterColorBot version 2.0!

WaterColorBot 2.0

The WaterColorBot is our collaboration with Super Awesome Sylvia: A friendly art robot that moves a paint brush to paint your digital artwork onto paper, using a set of watercolor paints.

Version 2.0 brings it to the next level with some greatly improved hardware. First and foremost, the carriage that holds the brush has been completely redesigned:

WaterColorBot 2.0

The carriage on the original WaterColorBot was made from laser-cut plywood, with nylon bushings and two simple delrin strips that formed the vertical flexure translation stage. (You can read more about the original carriage here and here.)

The new carriage consists mainly of two pieces of metal. The center block of anodized aluminum is CNC milled, and houses crossed linear roller bearings. Wrapped around that is a laser-cut and formed aluminum part that mounts the brush-lift motor, cable guide, and the flexure stage.

WaterColorBot 2.0

The new flexure stage is built with two custom flex circuit boards, used in this case as mechanical flexures. Each board consists of a very thin (0.1 mm, 4 mil) Kapton sheet with a thin fiberglass (G10/FR4) stiffener on its center section. With the two ends of each sheet clamped rigidly and the stiffener in the center, each flex circuit is to flex only along two well-defined lines. And with two boards, it forms a neat parallelogram linkage, without the slop that one might encounter in multi-part hinges. The net effect is that this new flexure stage has remarkable stiffness compared to the old design.

WaterColorBot 2.0

That stiffness, combined with the improved performance of the linear ball bearings makes this a more precise WaterColorBot. Not that you could even detect the improvement with a fat brush and watercolor paints, but things are looking quite good even with using ultra-fine point drawing pens, as you can see above.

WaterColorBot 2.0

The second major change is to the system of Spectra cords that the stepper motors control in order to move the carriage. Previously, the cords were guided around 11 plain bearings (stainless steel solid rivets) and 3 ball bearings.  We’ve simplified this into an arrangement of just 8 ball bearings— four for each motor. The ball bearing pulleys have also been updated to use wide V-groove bearings that are easy to wrap the cords around.

Which brings us to the third (and last) major change. Thus far, WaterColorBot kits have shipped “some assembly required” — with all the major components built, but the cord lacing left to the end user. As of 2.0, WaterColorBot kits now come fully assembled and tested. That doesn’t make them any less hackable, but it does mean that you can get up and running faster.

WaterColorBot 2.0

Version 2.0 includes the same CNC machined aluminum winches that we introduced back in August. Tiny detail: we’ve carved a subtle indentation into the wood around the winch that makes them a little easier to turn by hand.

WaterColorBot 2.0

The new WaterColorBot kits will begin to ship right after Thanksgiving. And a bonus present for the holiday season: Version 2.0 is priced the same as the previous version, it’s just a whole lot more awesome per dollar.

CNC Dragonfly Barrette

Dragonfly Barrette

When I saw Simone from Othermill running her machine this weekend, I told her about an idea I had for a metal dragonfly hair clip. She quickly grabbed the file from Sam DeRose’s Light-up PCB Pins tutorial. After carving the texture and doing the cutout, the only other tools needed to complete the project were a pair of pliers to bend the wings and some glue to affix it to a clip. It turned out great!