Saturday, February 7, 2015

Guerrilla guide to CNC machining, mold making, and resin casting

Guerrilla guide to CNC machining, mold making, and resin casting

Home manufacturing tutorial for robot builders, model makers, and other hobbyists

Lots of useful information.  

Rearden Metal coming soon?

Pure titanium metal in photo

Fans of Ayn Rand's 'Atlas Shrugged' will recognize this one

In a article published by Sang-Heon Kim, Hansoo Kim & Nack J. Kim of the  Graduate Institute of Ferrous Technology, POSTECH, Pohang 790-784, South Korea. 

They discovered a new alloy that combines Aluminum, Steel and a small amount of Nickel to make a metal as strong as Titanium.

Previous attempts at making this alloy resulted in brittleness because of the crystalline structure.  

Simply put it made hard yet brittle metal.

The Nickel on the other hand disperses the crystals so that they do not form as large, and in a structure that is both strong and light.

However full scale production is still a small ways off as the current mill process uses silicates to prevent steel from oxidizing during production. The silicates react with the process so another method will need to be devised.  Otherwise the whole process could be performed in existing mills without modification to equipment.

My hopes is that the laser sinter for 3D printing using ordinary $5 a pound Titanium dioxide powder becomes a reality as this alloy still will not have the heat resistant qualities of actual titanium.

Original links here since they want a couple hundred dollars to quote them directly:

References• Author information• Extended data figures and tables
Davis, S., Diegel, S. & Boundy, R. Transportation Energy Data Book 32nd edn, 4–17 (Oak Ridge National Laboratory, 2013)
Militzer, M. Materials science: a synchrotron look at steel. Science 298, 975–976 (2002)
Kim, H., Suh, D. W. & Kim, N. J. Fe-Al-Mn-C lightweight structural alloys: a review on the microstructures and mechanical properties. Sci. Technol. Adv. Mater. 14, 014205 (2013)
Suh, D. W. & Kim, N. J. Low-density steels. Scr. Mater. 68, 337–338 (2013)
Zargaran, A., Kim, H. S., Kwak, J. H. & Kim, N. J. Effects of Nb and C additions on the microstructure and tensile properties of lightweight ferritic Fe–8Al–5Mn alloy. Scr. Mater. 89, 37–40 (2014)
Sutou, Y., Kamiya, N., Umino, R., Ohnuma, L. & Ishida, K. High-strength Fe-20Mn-Al-C-based alloys with low density. ISIJ Int. 50, 893–899 (2010)
Frommeyer, G. & Brüx, U. Microstructures and mechanical properties of high-strength Fe-Mn-Al-C light-weight TRIPLEX steels. Steel Res. Int. 77, 627–633 (2006)
Gutierrez-Urrutia, I. & Raabe, D. Influence of Al content and precipitation state on the mechanical behavior of austenitic high-Mn low-density steels. Scr. Mater. 68, 343–347 (2013)
Gschneidner, K., Jr et al. A family of ductile intermetallic compounds. Nature Mater. 2, 587–591 (2003)
Kuc, D., Niewielski, G. & Bednarczyk, I. Structure and plasticity in hot deformed FeAl intermetallic phase base alloy. Mater. Charact. 60, 1185–1189 (2009)
Stoloff, N. S., Liu, C. T. & Deevi, S. C. Emerging applications of intermetallics. Intermetallics 8, 1313–1320 (2000)
Liu, C. T., Stringer, J., Mundy, J. N., Horton, L. L. & Angelini, P. Ordered intermetallic alloys: an assessment. Intermetallics 5, 579–596 (1997)
Cao, G. H. et al. Determination of slip systems and their relation to the high ductility and fracture toughness of the B2 DyCu intermetallic compound. Acta Mater. 55, 3765–3770 (2007)
Davies, R. G. Influence of martensite composition and content on the properties of dual phase steels. Metall. Trans. A 9, 671–679 (1978)
Thomser, C., Uthaisangsuk, V. & Bleck, W. Influence of martensite distribution on the mechanical properties of dual phase steels: experiments and simulation. Steel Res. Int. 80, 582–587 (2009)
Choi, K. et al. Effect of aging on the microstructure and deformation behavior of austenite base lightweight Fe-28Mn-9Al-0.8C steel. Scr. Mater. 63, 1028–1031 (2010)
Yoo, J. D. & Park, K. T. Microband-induced plasticity in a high Mn-Al-C light steel. Mater. Sci. Eng. A 496, 417–424 (2008)
Breuer, J., Grün, A., Sommer, F. & Mittemeijer, E. J. Enthalpy of formation of B2-Fe1-xAlx and B2-(Ni,Fe)1-xAlx. Metall. Mater. Trans. B 32, 913–918 (2001)
Chumak, I., Richter, K. W. & Ipser, H. Isothermal sections in the (Fe, Ni)-rich part of the Fe-Ni-Al phase diagram. J. Phase Equil. Diffus. 29, 300–304 (2008)
Leslie, W. C. The Physical Metallurgy of Steels 43–59 (TechBooks, 1981)
Richeton, T., Weiss, J. & Louchet, F. Breakdown of avalanche critical behaviour in polycrystalline plasticity. Nature Mater. 4, 465–469 (2005)
Gil, F. J., Manero, J. M., Ginebra, M. P. & Planell, J. A. The effect of cooling rate on the cyclic deformation of β-annealed Ti-6Al-4V. Mater. Sci. Eng. A 349, 150–155 (2003)
Tähtinen, S., Moilanen, P., Singh, B. N. & Edwards, D. J. Tensile and fracture toughness properties of unirradiated and neutron irradiated titanium alloys. J. Nucl. Mater. 307–311, 416–420 (2002)
Marmy, P. & Leguey, T. Impact of irradiation on the tensile and fatigue properties of two titanium alloys. J. Nucl. Mater. 296, 155–164 (2001)
Bowen, A. W. The influence of crystallographic orientation on tensile behaviour in strongly textured Ti6Al4V. Mater. Sci. Eng. 40, 31–47 (1979)
Dursun, T. & Soutis, C. Recent developments in advanced aircraft aluminium alloys. Mater. Des. 56, 862–871 (2014)
Merati, A. in Corrosion Fatigue and Environmentally Assisted Cracking in Aging Military Vehicles (RTO-AG-AVT-140) Ch. 24 (Research and Technology Organization, NATO, 2011)
Fan, D. W., Kim, H. S. & De Cooman, B. C. A review of the physical metallurgy related to the hot press forming of advanced high strength steel. Steel Res. Int. 80, 241–248 (2009)

Casting metal from 3D printed molds

Found this awhile back.

Pretty cool stuff.

Cast aluminum receivers anyone?

Friday, February 6, 2015

The further you go

The bigger, smaller, faster, slower, higher, lower, smarter, dumber, brighter, darker, you try to go. The difficulty increases exponentially.

Above: An attempt to engrave tiny name plates with plate marker

Below: Same file done with laser.

Thursday, February 5, 2015

How to Download Objects From the Internet

Today I will go thru step by step on how to download a physical object from the internet.

Note:  I will be using a 3D printer to make this object.  3D printers will make this file, although a small milling machine will make as well and the milling machine will be more accurate.

That said there are undercuts that make the necessary addition of registration pins if you are to make this with a 3 axis mill.

With a 3D printer there are no tooling changes.

First thing we need is a file.  Thingiverse is the most popular for 3D printers, but quality of the files and availability of useful items is rather limited compared to Traceparts.

TraceParts exists as a way for manufacturers to share their design files in the hopes that engineers will use those files and then order the parts from that particular supplier.

Generally these files are not made for 3D printing, but with care you can mod the file for printing and get a acceptable result.  Another cool thing is to download things like switches and hardware that you can print out to use as test pieces.  For example you are doing a mockup of a machine with some specialty switches, fittings etc.  You can download the parts, print them out and while they do not physically work, you did not spend the money buying something (and waiting for it to arrive) just to see what it would look like or how it would work in the real world.

Traceparts CAD files

Here is a example of a gear we would like to download

 We download this file and save to the computer

We then open the file in our CAD software.  In this case DesignSpark Mechanical
We set the export options in the file.  In this case we are using 0,9 degrees.  Since .stl files are a mesh that means that it is not a true curve, rather a polygonal mesh.  So we make the polygon angles small so that there are no visible facets in the finished item.

We open the file in our printer control and slicer software.  In this case Simplify3D

We set our resolution, print speed, infill and other settings

We pre-heat the 3D printer and then click on the begin printing

Drone Conversions: USGOV is Chicken Little

You saw my comments on Iran and how they are converting drones into cruise missiles.

Well more info is coming out from the DC establishment.  The news is; that they are 'Scared'.

Yes you heard that right.  DC is 'Scared' of losing their imaginary technological superiority.

They offer nothing in the way of ideology, or moral superiority, so they resort to the tried and true despot tactic of brute force. 

Except 4th gen warfare now evens out the odds.

Back hundreds of years ago, this warfare was rather common.  Nation states were not the omnipotent beings they once were. 

An armed ship and crew of a couple hundred could go out and pretty much do what they wanted in most of the world.  They were called many names.  Pirates, Conquistadors, Dutch East Indies Company etc.

The industrial revolution and WW1 really brought this to a halt with the rise of the super-army. 

However with the advent of the internet, and new methods of manufacturing.  The balance of power is now shifting away. 

My prediction?

More of the same but worse from the powers that be. 

The day will come when they will hunt down every maker, builder and thinker in their quest to keep power.  In the same way they presently hunt down Moslem bomb makers.

They will be changing the propaganda narrative and make me, you, and anybody who creates stuff outside the establishment permission into the bad guys.  

Yet it is the rise of the Luddites those who promise peace, prosperity, and anything else to keep power who engage in the most violence.  (religion of peace, UN peace keepers, etc etc)

The collectivists will fail, but they will kill millions on their way down.  For our own good you see...

UPDATE.  More hysteria.  This sounds like a coordinated propaganda push aimed at banning them.  

Monday, February 2, 2015

Do you understand yet?

New Raspberry Pi Computers Are Out

raspberry pi 2
New Raspberry Pi on the market.
Same $35 USD price.

So many uses for it.  It is a outstanding cheap webpage server, among many other uses.

Soon with Windows 10. 

  • A 900MHz quad-core ARM Cortex-A7 CPU (~6x performance)
  • 1GB LPDDR2 SDRAM (2x memory)
  • Complete compatibility with Raspberry Pi 1

Windows 10

The Raspberry Pi 2-compatible version of Windows 10 will be available free of charge to makers.

Now most people will say "So What" 

Well here is the un-reported innovation.

The standard controller for industrial automation.  The machines that make food, control heating, run gambling machines, you name it, are in large part run on Mitsubishi touch screen controllers that use Windows CE.

I was at a industrial automation firm awhile back where the engineer was showing off a new Mistubishi touchscreen controller that powers a packaging machine for powdered milk.

The controller measures the powder, and controls all the operations that go into transforming a roll of printed plastic film and a hopper full of powdered milk into packages of milk sold in the store. 

The controller cost almost $2000.

This controller along with appropriate touch screens and related gear will cost on the order of a couple hundred dollars at most (counting programming, accessories etc)

Windows CE is rather long in the tooth, but it stable.  So people who build factories use it. 

If this pi controller that uses windows 10 is as stable as the Mitsubishi controller, I think there will be a lot of layoffs at Mitsubishi.

Stability means  that the machine has to run 24/7 day after day without fail.  If it can do that, we will see the advancement of industrial automation and less labor being involved in making things. 

This is why you need to know these new skills.

There will be 2 types of workers in the future.  Those that program the bots or those that sweep the floors (and the floor sweeping will be automated too)

Even mundane tasks like farming and driving construction equipment will one day be automated.

3D printer driver chip assembly

stepstick drivers
Making this today.  

Driver chips for the 3D printer.  They arrive without the pins on them so they have to be assembled. 

Left is how the parts are aligned using a pre-drilled bread board.  Top are the parts, and bottom right is finished part.

The trick is using very fine silver solder wire and a lot of rosin core flux.  Of course the obvious steady hand and good eyesight are important too.

Sunday, February 1, 2015

Piercing the Government Veil

John Robb had an interesting article I just read about piercing the corporate veil and Sony in relation to their 'hack'.

 Why the Sony Hack Worked
The Sony hack worked.  It did the job it was intended to do.  It coerced a major corporation and its corporate partners into changing their behavior.  
It's a good example of a type of attack we are going to see much more of.
However, it's important to understand why it worked so well.  It wasn't due to:
  • its sophistication,
  • the damage it did to Sony's critical systems, or
  • the amount of money it stole.
It was effective because it went after employees and business partners as individuals.  
It was effective because it pierced the corporate veil by personally attacking every employee at Sony (and some of their business partners).

Now think about the same technique applied to the miscreants in your part of the world...

More recent examples:

A Sipsey Street Public Service Announcement: The Connecticut Tyrants List, voluntarily subscribed by the participants on 3 April 2013.
The state of Connecticut is making lists of firearm owners to raid. It seems obvious to me that it is thus only fair to list those anti-constitutional tyrants who will have blood on their hands the moment the first Connecticut citizen is shot by the CT state police while carrying out their orders. I will be sending these folks my own email later today.
CT State Senators voting Yes on "An Act Concerning Gun Violence Prevention and Children's Safety, also known as Public Law 13-3 or Connecticut Senate Bill No. 1160," 3 April 2013. List includes home addresses. Photos and home phone numbers of these tyrants are available here:

Historical examples:

 Now I am not advocating for the Vietcong Model.  I find the Vietcong abhorrent.

However one should have a grasp as to whom and what we are going up against.

The Sony incident shows that objectives can be achieved without firing a shot.

Another thing you need to understand as to who exactly is in charge of the current regime.  Its organizational methods and methods of advancement. 

For example here is just one bureaucrat.  This person is heavily involved in the communist movement and has used entry-ism techniques to gain power.

Dinah Leventhal

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Dinah Leventhal
Dinah Leventhal

DSA member

In 1991, Dinah Leventhal was Democratic Socialists of America Youth Organizer.[1]
Her term finished in June 1991[2]
That year, Leventhal married Patrick Lacefield. At the time she was working for a "progressive Maryland state senator".[3]


  1. Jump up Democratic Left, Jan./Feb. 1991, page 9
  2. Jump up Democratic Left, March/April 1991, page 2
  3. Jump up Democratic Left, Sept./Oct. 1991, page 23
or this guy

Carl Davidson is a Pennsylvania based acivist and member of the National Committee of the Committees of Correspondence for Democracy and Socialism.

Early life

Carl Davidson grew up in the small town of Alaquippe, Pennsylvania.

Early activism

Davidson participated in the Mississippi Freedom March.

Students for A Democratic Society activism  

One needs to think now days as information itself as the weapon.  This is why the other side is vacuuming up every scrap of information they can due to the following reasons:

1 Information is money.  Corporate espionage on a national governmental scale
2 Information is power.  The ability to blackmail any elected representative
3 Information is tactics.  The means to find any person of relevance in the world
4 information as the payload.  Info dumps are in themselves have been used as weapons.  

Sony, or Wikileaks are refined examples of methods that were more crudely done in the past.