Tag Archives: Aluminum

How to Build Anything Out of Aluminum Extrusion and 3D Printed Brackets

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The real power of 3D printing is in infinite customization of parts. This becomes especially powerful when you combine 3D printing with existing materials. I have been developing a few simple tricks to make generic fasteners and printed connectors a perfect match for aluminum extrusion, via a novel twist or two on top of techniques you may already know.

Work long enough with 3D printers, and our ideas inevitably grow beyond our print volume. Depending on the nature of the project, it may be possible to divide into pieces then glue them together. But usually a larger project also places …read more

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The Aluminum Wiring Fiasco

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Someone who decides to build a house faces a daunting task. It’s hard enough to act as the general contractor for someone else, but when you decide to build your own house, as my parents did in the early 1970s, it’s even tougher. There are a million decisions to make in an information-poor and rapidly changing environment, and one wrong step can literally cast in stone something you’ll have to live with forever. Add in the shoestring budget that my folks had to work with, and it’s a wonder they were able to succeed as well as they did.

It …read more

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This Vapour Deposition Chamber Isn’t Vapourware

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If you are an astronomer with an optical reflecting telescope, the quality of your mirror is one of your most significant concerns. Large observatories will therefore often have on-site vapour deposition plants to revitalise their reflectors by depositing a fresh layer of aluminium upon them. You might think that such a device would be the preserve only of such well-funded sites, but perhaps [Michael Koch]’s work will prove you wrong. He’s created his own vapour deposition system (Google Translate link of the German original) from scratch, and while it might be smaller than the institutional equivalents it is no less …read more

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Medium Machine Mediates Microcontroller Messages

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Connecting computers to human brains is currently limited to the scope of science fiction and a few cutting-edge laboratories. Tapping into some nerves farther from our central wetware is possible and [Peter Buczkowski] shows us his stylish machine for implanting a pattern into our brains without actively having to memorize anything.

His Medium Machine leverages a TENS unit to activate forearm muscles in a pattern programmed into an Arduino. Users place their forearm across two aluminum electrodes mounted on a tasteful wooden platform and extend a single finger over a button. Electrical impulses trigger the muscles which press the button. …read more

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What’s the Deal with Transparent Aluminum?

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It looks like a tube made of glass but it’s actually aluminum. Well, aluminum with an asterisk beside it — this is not elemental aluminum but rather a material made using it.

We got onto the buzz about “transparent aluminum” as a result of a Tweet from whence the image above came. This Tweet was posted by [Jo Pitesky], a Science Systems Engineer at the Jet Propulsion Lab in Pasadena. [Jo] reported that at a recent JPL technology open house she had the chance to handle a tube of material that looks for all the world like a section of …read more

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Robotic Arm Rivals Industrial Counterparts

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We’ve seen industrial robotic arms in real life. We’ve seen them in classrooms and factories. Before today, we’ve never mistaken a homemade robotic arm for one of the price-of-a-new-home robotic arms. Today, [Chris Annin] made us look twice when we watched the video of his six-axis robotic arm. Most of the DIY arms have a personal flare from their creator so we have to assume [Chris Annin] is either a robot himself or he intended to build a very clean-looking arm when he started.

He puts it through its paces in the video, available after the break, by starting with …read more

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3D Printing Aluminum with Nanoparticles

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We love our 3D printers. But sometimes we really wish we could print in metal. While metal printing is still out of reach for most of us, HRL Labs announced a powdered aluminum printing process that they claim is a breakthrough because it allows printing (and welding) of high-strength aluminum alloys that previously were unprintable and unweldable.

The key is treating the metal with special zirconium-based nanoparticles. The nanoparticles act as nucleation sites that allow the aluminum to form the correct microstructure. The full paper on the process appears in Nature.

Other than the nanoparticles, the process is a conventional …read more

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Pouring 1200° Tea: Foundry in a Fire Extinguisher

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Let’s face it — the design of most home foundries leaves something to be desired. Most foundries are great at melting metal, but when it comes to pouring the melt, awkward handling can easily lead to horrific results. That’s why we appreciate the thought that went into this electric melting pot foundry.

Sure, electric foundries lack some of the sex-appeal of gas- or even charcoal-fueled foundries, but by eschewing the open flames and shooting sparks, [Turbo Conquering Mega Eagle] was able to integrate the crucible into the foundry body and create what looks for all the world like a Thermos …read more

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The Tuna Fish Sandwich Foundry

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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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Custom Aluminum Wheels Teach a Thing or Two about Casting

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For some mobile projects like small carts or rolling cabinets, your standard casters from Harbor Freight will do just fine. But some projects need big, beefy wheels, and these custom cast aluminum wheels certainly make a statement. Mostly, “Watch your toes!”

To be honest, [Brian Oltrogge]’s wheels are an accessory in search of a project, and won’t be crushing feet anytime soon. He made them just to make them, but we have no beef with that. They’ve got a great look that hearkens back to a time when heavy metal meant something else entirely, and things were made to last. …read more

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