“Man And Machine” Vs “Man Vs Machine”

May 10, 2025 by Elliot Williams 10 Comments

Every time we end up talking about 3D printers, Al Williams starts off on how bad he is in a machine shop. I’m absolutely sure that he’s exaggerating, but the gist is that he’s much happier to work on stuff in CAD and let the machine take care of the precision and fine physical details. I’m like that too, but with me, it’s the artwork.

I can’t draw to save my life, but once I get it into digital form, I’m pretty good at manipulating images. And then I couldn’t copy that out into the real world, but that’s what the laser cutter is for, right? So the gameplan for this year’s Mother’s Day gift (reminder!) is three-way. I do the physical design, my son does the artwork, we combine them in FreeCAD and then hand it off to the machine. Everyone is playing to their strengths.

So why does it feel a little like cheating to just laser-cut out a present? I’m not honestly sure. My grandfather was a trained architectural draftsman before he let his artistic side run wild and went off to design jewellery. He could draw a nearly perfect circle with nothing more than a pencil, but he also used a French curve set, a pantograph, and a rolling architect’s ruler when they were called for. He had his tools too, and I bet he’d see the equivalence in mine.

People have used tools since the stone age, and the people who master their tools transcend them, and produce work where the “human” shines through despite having traced a curve or having passed the Gcode off to the cutter. If you doubt this, I’ll remind you of the technological feat that is the piano, with which people nonetheless produce music that doesn’t make you think of the hammers or of the tremendous cast metal frame. The tech disappears into the creation.

I’m sure there’s a parable here for our modern use of AI too, but I’ve got a Mother’s Day present to finish.

“Unnecessary” Automation Of A DIY Star Lamp Build

March 23, 2025 by Elliot Williams 10 Comments

It all started with a gift idea: a star-field lamp in the form of a concrete sphere with lightpipes poking out where the stars are, lit up from the inside by LEDs. When you’re making one of these, maybe-just-maybe you’d be willing to drill a thousand holes and fit a thousand little plastic rods, but by the time you’re making a second, it’s time to build a machine to do the work for you.

So maybe we quibble with the channel name “Unnecessary Automation,” but we won’t quibble with the results. It’s a machine that orients a sphere, drills the hole, inserts the plastic wire, glues it together with a UV-curing glue, and then trims the end off. And if you like crazy machines, it’s a beauty.

The video goes through all of the design thoughts in detail, but it’s when it comes time to build the machine that the extra-clever bits emerge. For instance, [UA] used a custom 3D-printed peristaltic pump to push the glue out. Taking the disadvantage of peristaltic pumps – that they pulse – as an advantage, a custom housing was designed that dispensed the right amount between the rollers. The rolling glue dispenser mechanism tips up and back to prevent drips.

There are tons of other project-specific hacks here, from the form on the inside of the sphere that simplifies optic bundling and routing to the clever use of a razor blade as a spring. Give it a watch if you find yourself designing your own wacky machines. We think Rube Goldberg would approve. Check out this video for a more software-orientated take on fiber-optic displays.

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Generative Art Machine Does It One Euro At A Time

March 22, 2025 by Elliot Williams 14 Comments

[Niklas Roy] obviously had a great time building this generative art cabinet that puts you in the role of the curator – ever-changing images show on the screen, but it’s only when you put your money in that it prints yours out, stamps it for authenticity, and cuts it off the paper roll with a mechanical box cutter.

If you like fun machines, you should absolutely go check out the video, embedded below. The LCD screen has been stripped of its backlight, allowing you to verify that the plot exactly matches the screen by staring through it. The screen flashes red for a sec, and your art is then dispensed. It’s lovely mechatronic theater. We also dig the “progress bar” that is represented by how much of your one Euro’s worth of art it has plotted so far. And it seems to track perfectly; Bill Gates could learn something from watching this. Be sure to check out the build log to see how it all came together.

You’d be forgiven if you expected some AI to be behind the scenes these days, but the algorithm is custom designed by [Niklas] himself, ironically adding to the sense of humanity behind it all. It takes the Unix epoch timestamp as the seed to generate a whole bunch of points, then it connects them together. Each piece is unique, but of course it’s also reproducible, given the timestamp. We’re not sure where this all lies in the current debates about authenticity and ownership of art, but that’s for the comment section.

If you want to see more of [Niklas]’s work, well this isn’t the first time his contraptions have graced our pages. But just last weekend at Hackaday Europe was the first time that he’s ever given us a talk, and it’s entertaining and beautiful. Go check that out next. Continue reading “Generative Art Machine Does It One Euro At A Time” →

Paper Punching Machine Looks Like Cute Piece Of Computer History Past

September 13, 2023 by Lewin Day 23 Comments

Computing used to run on punch cards. Great stacks of cards would run middling programs, with data output onto more punched cards in turn. [Nii] has built a machine in this vein, capable of punching binary into paper tape.

The machine is run by a stepper motor, which is charged with feeding the paper tape through the machine in steady steps. A series of vertically-actuated solenoids punch holes in the paper tape as directed. The machine buzzes and clicks away like the best electromechanical computing devices of the mid-century era.

To what end, we couldn’t possibly say. One user noted the machine was punching seemingly random binary into the paper tape, and [Nii] has not provided any explanation as to the machine’s higher purpose. Regardless, whatever it is doing, it looks like it’s doing it well. Feel free to speculate in the comments.

Impressively, the petite device will be demonstrated at MF-TOKYO, the 7th Annual Metal Forming Fair in Tokyo this year. We’re sure the clickity-clack will be muchly appreciated in person. Video after the break.

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A person holds a bundle of white, black, and blue wires. The left hand side of the wires are wrapped with black tape. The wires are inside a wire wrapping machine with a grey plastic "C" which rotates inside seven small pulleys. A large pulley in the background drives three of the pulleys to rotate the "C" around and wrap the wires with tape from the spool attached to the "C."

DIY Tool Makes Wrapping Wiring Harnesses A Breeze

February 26, 2023 by Navarre Bartz 17 Comments

If you’re making a lot of wiring harnesses, wrapping them can become a bit of a drag. [Well Done Tips] wanted to make this process easier and built a wiring harness wrapping machine.

The “C” shape of this wrapping machine means that you can wrap wires that are still attached at one or both ends, as you don’t have to pull the wires all the way through the machine. The plastic “C” rotates inside a series of pulleys with three of them driven by a belt attached to an electric motor. A foot pedal actuates the motor and speed is controlled by a rotary dial on the motor controller board.

Since this is battery powered, you could wrap wires virtually anywhere without needing to be near a wall outlet. This little machine seems like it would be really great if you need to wrap a ton of wire and shouldn’t be too complicated to build. Those are some of our favorite hacks.

If you’re wanting more wire harness fun, try this simple online wiring harness tool or see how the automotive industry handles harnesses.

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Cut Your Own Gears With This DIY Machine

January 27, 2023 by Lewin Day 29 Comments

You can buy gears off the shelf, of course, and get accurately machined parts exactly to your chosen specification. However, there’s something rugged and individualist about producing your own rotating components. [Maciej Nowak] demonstrates just how to produce your own gears with a homemade cutting tool.

The cutting tool for the job is an M16 machine tap, chosen for the smaller flutes compared to a hand tap. This makes it more suitable for cutting gears. It’s turned by a belt driven pulley, run by a small motor. The workpiece to be cut into a gear is then fed into the cutting tool by sliding on a linear bearing, with its position controlled by a threaded rod. The rod can be slowly turned by hand to adjust the workpiece position, to allow the gear teeth to be cut to an appropriate depth.

The method of action is simple. As the tap turns it not only cuts into the workpiece, but rotates it on a bearing as well. By this method, it cuts regular teeth into the full circumference, creating a gear. Obviously, this method doesn’t create highly-complex tooth shapes for ultimate performance, but it’s more than capable of creating usable brass and steel gears for various purposes. The same tool can be used to cut many different sizes of gear to produce a whole geartrain. As a bonus, the resulting gears can be used with M16 threads serving as worm gears, thanks to the pitch of the tap.

If you find yourself needing to produce tough metal gears on the regular, you might find such a tool very useful. Alternatively, we’ve explored methods of producing your own sprockets too, both in a tidy manner, and in a more haphazard fashion. Video after the break.

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Using Statistics Instead Of Sensors

April 3, 2022 by Bryan Cockfield 9 Comments

Statistics often gets a bad rap in mathematics circles for being less than concrete at best, and being downright misleading at worst. While these sentiments might ring true for things like political polling, it hides the fact that statistical methods can be put to good use in engineering systems with fantastic results. [Mark Smith], for example, has been working on an espresso machine which can make the perfect shot of coffee, and turned to one of the tools in the statistics toolbox in order to solve a problem rather than adding another sensor to his complex coffee-brewing machine.

To make espresso, steam is generated which is then forced through finely ground coffee. [Mark] found that his espresso machine was often pouring too much or too little coffee, and in order to improve his machine’s accuracy in this area he turned to the linear regression parameter R², also known as the coefficient of determination. By using a machine learning algorithm tuned to this value, which assesses predictable variation in a data set, a computer can more easily tell when the coffee begins pouring out of the portafilter and into the espresso cup based on the pressure and water flow in the machine itself rather than using some other input such as the weight of the cup.

We have seen in the past how seriously [Mark] takes his coffee-making, and this is another step in a series of improvements he has made to his equipment. In this iteration, he has additionally produced a simulation in JupyterLab to better assist him in modeling the system and making even more accurate predictions. It’s quite a bit more effort than adding sensors, but since his espresso machine already included quite a bit of computing power it’s not too big a leap for him to make.