Scrap Microwave Spot Welder

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This project involves AC power, high amperage, and high temperatures. Although this project is simple in principle replicating it on your own offers a lot of opportunities to hurt yourself. Proceed with caution.

Microwaves are treasure troves of useful electronic components. They’ve usually got some nice microswitches, a big transformer, a magnetron, and some smaller transformers and rectifiers to drive the display. I found a decent sized microwave hanging out on the street and transformed it into a shop tool I’d been wanting for a while – a spot welder.

Why Spot Welders are Useful

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Spot welders are handy to have around the shop. They can tack together wire for quick brazing, and permanently weld sheet metal for durable enclosures. If you want a thorough guide on what you can do with a spot welder, Dan Gelbart has all the answers. I’ve been looking to up my prototyping game and have more freedom to build custom components when off the shelf parts won’t suit. Unfortunately my workshop is in Brooklyn and space is at a premium. I spent a lot of time fabricating structures out of steel wire in school and have found that it’s a good replacement for bent sheet metal and structural framing if you play your cards right. Wire is easy to store in a small shop, doesn’t take much equipment to manipulate, and can hold good tolerances in various dimensions as its behavior is very predictable. You can still find the manual I follow for a lot of my techniques on Amazon. Continue reading

DIY Infusions – Cocktail Fuel

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I’m fond of giving people gifts, but often shy away from just giving people stuff. There’s a complex dance of figuring out if it’ll be useful, if the quality’s any good, if they’ve already got one around, that muddies the water. I prefer to make something that doesn’t take up much space and has the chance of getting used up rather than living out the rest of its existence in storage. I’ve found that infusions work pretty perfectly for this job.

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I’ve gone through a lot of recipes and variations over the years (they’ll likely show up on this blog eventually) but I was especially fond of this batch made in 2013. I made 5 infusions as christmas gifts to send to friends and family. The mixes were black pepper vodka, pumpkin vodka, lady grey tea gin, raw honey vodka, and red pepper tequila. Continue reading

SOLS Adaptiv – A Wearable Soft Robot

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I was hired by SOLS to help out with their Adaptiv project. The idea was to showcase the procedural modeling techniques, materials, and technologies behind their printed insoles with a futuristic robotic shoe. Jordan Dialto, the industrial design lead at SOLS, approached me in my capacity as lead scientist at Super-Releaser to make a prototype soft robot shoe that could change shape and fit in response to the wearer.

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The external shell (purple) retaining skeleton (grey) and soft actuators (teal) joined together with reference pins to be inserted into the original mesh.

The project started out with an external shell modeled by Continuum Fashion. Although the design was elegant, this posed a challenge for introducing the robotic elements and the engineered components that would stitch everything together. Since the external shell was generated in a mesh CAD program, it didn’t fit into SolidWorks’ reference frame. This meant using the mesh as a reference and generating a simplified surface to extrude the soft robot elements and retaining skeleton from. Continue reading

Glowy Crystal Ring

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Do you like 3D printing, mold making, industrial design, jewelry, and RGB LED’s? You’re in luck, then. I just finished this tutorial for Adafruit and think it’s well worth a look.

In this project, I attempted to make an Arduino powered device that was easy to use, easy to make, and self contained. Every 3d printed component can be done in a single build without support material. The ring has a battery, switch, and USB port. Once it’s together, all you need to charge or reprogram it is a USB Micro cable.

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Soft Robots in Space

Soft Robots in Space

I spoke at the NYC NASA SpaceApps conference last weekend about how soft robots might end up in space in the next few years. I covered mechanical counterpressure suits, exercise on the International Space Station, enhancing strength on EVA’s, and how space turns your heart into a sphere. Stick around for the Q&A segment at the end, where I get to field some questions from real-life astronaut Catherine Coleman.

You can see my slides here.

Soft Robotics Talks at NYCResistor

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I’m trying to get more people playing with soft robots. I’m releasing open source design files, tutorials, and now teaching classes. They’re a useful tool to add to any roboticist’s engineering toolbox, and if they were more widely known I think we’d see them outside the research lab and applied to practical problems.

I’ve taught a couple of seminars on soft robotics (demonstrating how I fabricate the Glaucus) over the last few weeks. I’m also giving a few talks soon – one at a seminar for engineering simulations, and another at NYC’s Spaceapps Hackathon.

You can find more information on the last few classes on the Soft Robotics Technology Meetup page, the ACM-NYC Meetup page, and NYCResistor’s blog. I’ve embedded video of the ACM talk below.

 

Title photo by David Rey. You can find more of his photos of this event at the NYC Soft Robotics Technology Group Meetup here.

“Hard Problems? Soft Robots!” at BsidesHH 2014

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I’ve been going to CCC for a while. I’ve given some talks (mostly on the lightning talk track) and have generally had a good time. More and more, though, I’ve gotten interested in gatherings that orbit big events like CCC, Maker Faire, and HOPE. Unconferences, Bsides, and nether-conferences like BarCamp are less formal than a traditional conference, and often have the kind of wiggle room for instant breakout sessions and long Q&A.

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Print Your Own Robot: Part 10

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Long time no see, folks. I’ve got some great news for you. I’ve finally found a method for getting super complicated geometry locked inside of a seamless skin. It’s taken a lot of prototypes to get here, but I think the results are more than worth the effort. There are some wrinkles to iron out (which I’ll get to below) but all in all I think I’m incredibly close to rapid-fire casting working quadrupeds, ready to go in just a few short steps after popping the mold. In other good news, I’ll be dropping some files very soon which should get you your very own working quadruped using any FDM printer. All you need is a Makerbot or similar, a few hours, and some casting materials to have an exact duplicate of my most sophisticated robot to date.

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Soft Robots

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I’ve been working on this project for a few months, focused on changing how soft robots get designed and made. Traditionally these robots are complex to design and build, and they require and unexpectedly large amount of hand labor to stitch together. This ends up with parts being produced slowly, with small deviations from known working designs. I’ve been trying to come up with a method that allows you to design a robot in CAD, queue up the design on a powder printer, cast silicone into the printed mold, and pull out a working robot. The idea is to allow for a huge variety of geometry, experimentation, and prototypes that are quick and inexpensive to produce. I want to make the process a whole lot more like a scientific experiment, where you test and observe multiple samples while adjusting a single variable. Continue reading