3D Printing A Useful Fixturing Tool

24 Abril 2025 at 23:00

When you start building lots of something, you’ll know the value of accurate fixturing. [Chris Borge] learned this the hard way on a recent mass-production project, and decided to solve the problem. How? With a custom fixturing tool! A 3D printed one, of course.

Chris’s build is simple enough. He created 3D-printed workplates covered in a grid of specially-shaped apertures, each of which can hold a single bolt. Plastic fixtures can then be slotted into the grid, and fastened in place with nuts that thread onto the bolts inserted in the base. [Chris] can 3D print all kinds of different plastic fixtures to mount on to the grid, so it’s an incredibly flexible system.

3D printing fixtures might not sound the stoutest way to go, but it’s perfectly cromulent for some tasks. Indeed, for [Chris]’s use case of laser cutting, the 3D printed fixtures are more than strong enough, since the forces involved are minimal. Furthermore, [Chris] aided the stability of the 3D-printed workplate by mounting it on a laser-cut wooden frame filled with concrete. How’s that for completeness?

We’ve seen some other great fixturing tools before, too. Video after the break.

Low Cost Oscilloscope Gets Low Cost Upgrades

Hackaday

Bryan Cockfield

20 Abril 2025 at 14:00

Entry-level oscilloscopes are a great way to get some low-cost instrumentation on a test bench, whether it’s for a garage lab or a schoolroom. But the cheapest ones are often cheap for a reason, and even though they work well for the price they won’t stand up to more advanced equipment. But missing features don’t have to stay missing forever, as it’s possible to augment them to get some of these features. [Tommy’s] project shows you one way to make a silk purse from a sow’s ear, at least as it relates to oscilloscopes.

Most of the problem with these lower-cost tools is their low precision due to fewer bits of analog-digital conversion. They also tend to be quite noisy, further lowering the quality of the oscilloscope. [Tommy] is focusing his efforts on the DSO138-mini, an oscilloscope with a bandwidth of 100 kHz and an effective resolution of 10 bits. The first step is to add an anti-aliasing filter to the input, which is essentially a low-pass filter that removes high frequency components of the signal, which could cause a problem due to the lower resolution of the device. After that, digital post-processing is done on the output, which removes noise caused by the system’s power supply, among other things, and essentially acts as a second low-pass filter.

In part 2 of the project, [Tommy] demonstrates the effectiveness of these two methods with experimental data, showing that a good percentage of the noise on a test signal has been removed from the output. All the more impressive here is that the only additional cost besides the inexpensive oscilloscope itself is for a ceramic capacitor that costs around a dollar. We were also impressed: [Tommy] is a junior in high school!

Presumably, you could apply these techniques to other inexpensive equipment, like this even cheaper oscilloscope based on the ESP32.

KiCad 9 Moves Up In The Pro League

Hackaday

Arya Voronova

22 Febrero 2025 at 21:00

Demonstration of the multichannel design feature, being able to put identical blocks into your design, only route one of them, and have all the other blocks' routing be duplicated

Do you do PCB design for a living? Has KiCad been just a tiny bit insufficient for your lightning-fast board routing demands? We’ve just been graced with the KiCad 9 release (blog post, there’s a FOSDEM talk too), and it brings features of the rank you expect from a professional-level monthly-subscription PCB design suite.

Of course, KiCad 9 has delivered a ton of polish and features for all sorts of PCB design, so everyone will have some fun new additions to work with – but if you live and breathe PCB track routing, this release is especially for you.

One of the most flashy features is multichannel design – essentially, if you have multiple identical blocks on your PCB, say, audio amplifiers, you can now route it once and then replicate the routing in all other blocks; a stepping stone for design blocks, no doubt.

Other than that, there’s a heap of additions – assigning net rules in the schematic, dragging multiple tracks at once, selectively removing soldermask from tracks and tenting from vias, a zone fill manager, in/decrementing numbers in schematic signal names with mousewheel scroll, alternate function display toggle on symbol pins, improved layer selection for layer switches during routing, creepage and acute angle DRC, DRC marker visual improvements, editing pad and via stacks, improved third-party imports (specifically, Eagle and Altium schematics), and a heap of other similar pro-level features big and small.

Regular hackers get a load of improvements to enjoy, too. Ever wanted to add a table into your schematic? Now that’s doable out of the box. How about storing your fonts, 3D models, or datasheets directly inside your KiCad files? This, too, is now possible in KiCad. The promised Python API for the board editor is here, output job templates are here (think company-wide standardized export settings), there’s significantly more options for tweaking your 3D exports, dogbone editor for inner contour milling, big improvements to footprint positioning and moving, improvements to the command line interface (picture rendering in mainline!), and support for even more 3D export standards, including STL. Oh, add to that, export of silkscreen and soldermask into 3D models – finally!

Apart from that, there’s, of course, a ton of bugfixes and small features, ~1500 new symbols, ~750 footprints, and, documentation has been upgraded to match and beyond. KiCad 10 already has big plans, too – mostly engine and infrastructure improvements, making KiCad faster, smarter, and future-proof, becoming even more of impressive software suite and a mainstay on an average hacker’s machine.

For example, KiCad 10 will bring delay matching, Git schematic and PCB integrations, PNG plot exports, improved diffpair routers, autorouter previews, design import wizard, DRC and length calculation code refactoring, part height support, and a few dozen other things!

We love that KiCad updates yearly now. Every FOSDEM, we get an influx of cool new features into the stable KiCad tree. We’re also pretty glad about the ongoing consistent funding they get – may they get even more, in fact. We’ve been consistently seeing hackers stop paying for proprietary PCB software suites and switching to KiCad, and hopefully some of them have redirected that money into a donation towards their new favorite PCB design tool.

Join the pro club, switch to the new now-stable KiCad 9! If you really enjoy it and benefit from it, donate, or even get some KiCad merch. Want to learn more about the new features? Check out the release blog post (many cool animations and videos there!), or the running thread on KiCad forums describing the new features&fixes in length, maybe if you’re up for video format, check out the KiCad 9 release talk recording (29m48s) from this year’s FOSDEM, it’s worth a watch.

Tricked Out Miter Fence Has All the Features

Hackaday

Dan Maloney

22 Febrero 2025 at 09:00

“World’s best” is a mighty ambitious claim, regardless of what you’ve built. But from the look of [Marius Hornberger]’s tricked-out miter fence, it seems like a pretty reasonable claim.

For those who have experienced the torture of using the standard miter fence that comes with machine tools like a table saw, band saw, or belt sander, any change is likely to make a big difference in accuracy. Miter fences are intended to position a workpiece at a precise angle relative to the plane of the cutting tool, with particular attention paid to the 90° and 45° settings, which are critical to creating square and true joints.

[Marius] started his build with a runner for the T-slot in his machine tools, slightly undersized for the width of the slot but with adjustment screws that expand plastic washers to take up the slack. An aluminum plate equipped with a 3D printed sector gear is attached to the runner, and a large knob with a small pinion mates to it. The knob has 120 precisely positioned slots in its underside, which thanks to a spring-loaded detent provide positive stops every 0.5°. A vernier scale also allows fine adjustment between positive stops, giving a final resolution of 0.1°.

Aside from the deliciously clicky goodness of the angle adjustment, [Marius] included a lot of thoughtful touches. We particularly like the cam-action lock for the angle setting, which prevents knocking your fine angle adjustment out of whack. We’re also intrigued by the slide lock, which firmly grips the T-slot and keeps the fence fixed in one place on the machine. As for the accuracy of the tool, guest meteorologist and machining stalwart [Stefan Gotteswinter] gave it a thumbs-up.

[Marius] is a veteran tool tweaker, and we’ve featured some of his projects before. We bet this fence will see some use on his much-modified drill press, and many of the parts for this build were made on his homemade CNC router.