A 3D Printed, Open Source Lathe?

October 23, 2024 by Dave Rowntree 35 Comments

[Chris Borge] has spent the last few years creating some interesting 3D printed tools and recently has updated their 3D printable lathe design to make a few improvements. The idea was to 3D print the outer casing of the lathe in two parts, adding structural parts where needed to bolt on motors and tool holders, and then fill the whole thing with concrete for strength and rigidity.

The printed base is initially held together with two lengths of studding, and a pile of bolts are passed through from below, mating with t-nuts on the top. 2020 extrusion is used for the motor mount. The headstock is held on with four thread rods inserted into coupling nuts in the base. The headstock unit is assembled separately, but similarly; 3D printed outer shell and long lengths of studding and bolts to hold it together. Decent-sized tapered roller bearings make an appearance, as some areas of a machine tool really cannot be skrimped. [Chris] explains that the headstock is separate because this part is most likely to fail, so it is removable, allowing it to be replaced.

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Lathe Outfitted With Electronic Gearbox

September 19, 2024 by Bryan Cockfield 45 Comments

Running a metal lathe is not for the faint of heart. Without proper knowledge and preparation, these machines can quickly cause injury or destroy expensive stock, tools, or parts. The other major problem even for those with knowledge and preparedness is that some of their more niche capabilities, like cutting threads with a lead screw, can be tedious and complicated thanks to the change gear system found on some lathes. While these are useful tools for getting things done, [Not An Engineer] decided that there was a better way and got to work building an electronic gearbox to automate the task of the traditional mechanical change gear setup in this video.

What makes change gears so tricky is that they usually come as a set of many gears of different ratios, forcing the lathe operator to figure out the exact combination of gears needed to couple the spindle of the lathe to the feed screw at the precise ratio needed for cutting a specific thread pattern. It is possible to do this task but can be quite a headache. [Not An Engineer] first turned to an Arduino Nano to receive input from a rotary encoder connected to the shaft of the lathe and then instruct a motor to turn the feed screw at a set ratio.

The first major problem was that the Arduino was not nearly fast enough to catch every signal from the encoder, leading to a considerable amount of drift in the output of the motor. That was solved by upgrading to a Teensy 4.1 with a 600 MHz clock speed. There was still one other major hurdle to cross; the problem of controlling the motor smoothly when an odd ratio is selected. [Not An Engineer] used this algorithm to inspire some code, and with that and some custom hardware to attach everything to the lathe he has a working set of electronic change gears that never need to be changed again. And, if you don’t have a lathe at all but are looking to get started with one, you can always build your own from easily-sourced parts.

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This Tiny Steam Engine Takes A Watchmaker’s Skill To Build

September 9, 2024 by Dan Maloney 29 Comments

When your steam engine build requires multiple microscopes, including those of the scanning electron variety, you know you’re building something really, really tiny.

All of the usual tiny superlatives and comparisons apply to [Chronova Engineering]’s latest effort — fits on a pencil eraser, don’t sneeze while you’re working on it or you’ll never find it. If we were to put the footprint of this engine into SMD context, we’d say it’s around a 2010 or so. As one would expect, the design is minimalistic, with no room for traditional bearings or valves. The piston and connecting rod are one piece, meaning the cylinder must pivot, which provides a clever way of switching between intake and exhaust. Tiny crankshaft, tiny flywheel. Everything you’d associate with a steam engine is there, but just barely.

The tooling needed to accomplish this feat is pretty impressive too. [Chronova] are no strangers to precision work, but this is a step beyond. Almost everything was done on a watchmaker’s lathe with a milling attachment and a microscope assist. For the main body of the engine, a pantograph engraving machine was enlisted to scale a 3D printed template down tenfold. Drill bits in the 0.3 mm range didn’t fare too well against annealed tool steel, which is where the scanning electron microscope came into play. It revealed brittle fractures in the carbide tool, which prompted a dive down the rabbit hole of micro-machining and a switch to high-speed steel tooling.

It all worked in the end, enough so that the engine managed 42,000 RPM on a test with compressed air. We eagerly await the equally tiny boiler for a live steam test.

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Tiny Orrery Is A Watchmaker’s Tour De Force

May 30, 2024 by Dan Maloney 3 Comments

Six tiny gears, a few fancy pins, and some clever casting are what it takes to build this tiny orrery. And patience — a lot of patience, too.

As model solar systems go, this one is exceptionally small. Its maker, [Mike] from Chronova Engineering, says it measures about 20 mm across and qualifies as the smallest orrery around. We can’t officiate that claim, but we’re not going to argue with it either. It’s limited to the Sun-Earth-Moon system, and while not as complete as some other models we’ve seen, it’s still exquisitely detailed. The gears that keep the Moon rotating 12.4 times around the Earth for each rotation of our home planet around the Sun are tiny, and take an abundance of watchmaking skill to pull off.

The video below shows the whole process, which is absolutely entrancing to watch. There are some neat tricks on display, from milling out the arms of the main wheel using a powered tailstock spindle to casting the Sun from resin in a silicone mold. The final model, with the model Earth and Moon spinning around the Sun on delicate brass wheels, is a visual treat.

We’ve seen some interesting stuff from Chronova Engineering lately, including this bimetallic tea timer.

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No Lathe? Build Your Own

April 12, 2024 by Al Williams 16 Comments

If you need to make round things, you probably need a lathe. Can you build one as nice as one you can buy? Probably not. But can you build one that will work and allow you to do more things than having no lathe at all? [Mikeandmertle] say absolutely! You can see the contraption in operation in the video below.

The build is decidedly functional-looking and only requires a few parts. Most of the components are unremarkable, save for a threaded bar, a metal pipe, some bearings, and a few threaded inserts. Well, there’s also a drill chuck and two lathe centers. Those don’t have to be very expensive, but they may well be the bulk of what you have to spend to make this project.

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There’s Hope For That Cheap Lathe Yet!

February 25, 2024 by Jenny List 30 Comments

There may be few cases where the maxim that “you get what you pay for” rings true, than a lathe. The less you spend on a lathe, the closer you get to a lathe-shaped object and the further from, well, a lathe. [Camden Bowen] has bought a cheap lathe, and he’s not content with a lathe-shaped object, so he takes us in the video below through a set of upgrades for it. In the process he makes a much nicer lathe for an entirely reasonable sum.

First up are the bearings, in this case a set of ball races which aren’t really appropriate for taking lateral force. After a lot of effort and a tiny bit of damage he manages to remove the old bearings and get the new ones in place, though their slightly different dimensions means he has to replace a spacer with a temporary 3D printed item which he’ll turn in metal later. We learn quite a bit about cheap lathe tools and tool alignment along the way, and he ends up buying a better tool post to solve some of its problems. We were always not very good at grinding HSS edges, too.

At the end of it all he has a much better lathe, upping cost from $774 to $1062 which is still pretty good for what he has. Worth a look, if you too have a lathe-shaped object.

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Creating A New Metal Rohde & Schwarz EB200 Miniport Receiver Dial Knob

October 30, 2023 by Maya Posch 6 Comments

Recently [Roberto Barrios] got his hands on a Rohde & Schwarz EB200 monitoring and surveillance receiver that, despite its late 90s vintage, was in mint condition. Aside from damage to the main dial, that is, which was very much broken. With no off-the-shelf replacement available in 2023, the obvious answer was to get a close-enough dial knob with the rough proportions and use a lathe to machine it into shape. Initially, [Roberto] had used some filler material to replace the front of the original knob that was missing, but this was a decidedly inferior tactile experience with questionable long-term reliability.

Dimensions of the Rhode & Schwarz EB200 dial knob. (Credit: Roberto Barrios)

The challenge in replacing the original knob with a proper replacement was in how the dial knob is mounted on the receiver, as an internally threaded shell that goes on the internal dial encoder assembly. With a lathe at his behest, taking an off-the-shelf dial knob that accepts a 6 mm shaft and turning it into a compatible knob was a straightforward affair. Removing the excess material and creating the internal 1 mm pitch thread allowed the newly made knob to fit on the receiver like an OEM part. The only niggle was having to remove 1.8 mm off the face of the brass body to get the knob to sit close to the front panel.

Unlike the old patched-up knob, this new one is fully out of metal and has the absolutely essential feature of the recessed area for easy fine-tuning. Although perhaps not the most exciting fix for old gear, it’s decidedly essential to keep it functional.