{"id":789,"date":"2011-12-29T17:29:10","date_gmt":"2011-12-29T22:29:10","guid":{"rendered":"http:\/\/bardagjy.com\/?p=789"},"modified":"2012-04-19T01:26:24","modified_gmt":"2012-04-19T06:26:24","slug":"how-to-make-almost-anything","status":"publish","type":"post","link":"https:\/\/bardagjy.com\/?p=789","title":{"rendered":"How to Make (almost) Anything"},"content":{"rendered":"

\nDuplication of my final post for HTMAA. Grand overview of my final project and a few greatest hits.\n<\/p>\n

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\nTeaser!<\/i>\n<\/p>\n

\nQuick preview of my final project, but first some “greatest hits”. I put most of this work in the content repo, the pictures link to the respective project pages.\n<\/p>\n

FabISPkey<\/a><\/h2>\n

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\nFabISP remixed.<\/i>\n<\/p>\n

\nI remixed the FabISP to a FabISPkey, doing away with the USB connector, and shrinking the layout a little. I also updated the design with a level shifter for low voltage targets – click the picture for more details!\n<\/p>\n

Anduino<\/a><\/h2>\n

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\nAnduino, shield compatible Arduino clone.<\/i>\n<\/p>\n

\nI put together a single sided, shield compatible Arduino clone, the Anduino. It’s been through quite a few revisions by now, and it now boasts, options for using different crystals and regulators, easier to solder headers and LEDs!\n<\/p>\n

Eagle Makefiles<\/a><\/h2>\n

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\nEagle Makefile<\/i>\n<\/p>\n

\nTo quickturn PCBs as I’ve been doing all semester, I’ve developed some tools. I don’t think they’ve been adopted by anyone in the class, but I’ve relied heavily on them and would love to see wider use.\n<\/p>\n

Things that Fly!<\/h2>\n

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\nInitial sketches.<\/i><\/p>\n

\nIt all starts with a sketch of key dimensions (in Autodesk Inventor).\n<\/p>\n

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\nModel with the trimmings<\/i><\/p>\n

\nThe fleshed out cad model as of 12\/12\/11. Note the nice aerodynamic shrouds. I even modeled the standoffs and screws! Pretty accurate weight and CG estimate in this model, problem was, I had no idea what kind of thrust to expect… (more later)\n<\/p>\n

\nSo let’s start making!\n<\/p>\n

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\nWhat happens when the lasercutter tries to cut outside its bounds.<\/i>\n<\/p>\n

\nSo it turns out that when the lasercutter tries to cut outside its limits, it flakes out and CUTS THE PART IN HALF. Back to the drawing board<\/strike> modeling tools.\n<\/p>\n

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\nLess sexy, but more buildable model.<\/i>\n<\/p>\n

\nTo make it fabricatable, I had to dial back the sexyness – and the size. And look! I made the foam pink! Let’s try the lasercutter again… (but first in cardboard because I’m extra paranoid now)\n<\/p>\n

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\nIt happened again! Good thing I was testing in cardboard<\/i>\n<\/p>\n

\nIt happened again! Good thing I was testing in cardboard. Shuffled some things around in Corel Draw, try again…\n<\/p>\n

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\nSuccess!<\/i>\n<\/p>\n

\nSuccess! On to cut the wooden model.\n<\/p>\n

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\nCutting out the frame.<\/i>\n<\/p>\n

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\nCut frame parts.<\/i>\n<\/p>\n

\nSuccess! Now, what to do about that foam… I need a really large piece to be aerodynamic (props are 2.5″ above the deck). I’ll try to glue it.\n<\/p>\n

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\nLaminating foam with ~500# of used garnet on it.<\/i>\n<\/p>\n

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\nGorilla glue in action. Get the parts a little wet to jumpstart the cure.<\/i>\n<\/p>\n

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\nDespite all of that weight, the Gorilla glue still managed to push the foam upwards.<\/i>\n<\/p>\n

\nSo the Gorilla glue still managed to push apart the two pieces of foam despite ~500# holding it down. Back to the drawing board again!\n<\/p>\n

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\nI’ll cut out half (well a quarter) of the shroud at a time and laminate them together in post.<\/i>\n<\/p>\n

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\nToe-clamping the foam to the bed – much more secure than screws.<\/i>\n<\/p>\n

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\nShopbot cutting out pink foam.<\/i>\n<\/p>\n

\nShopbot cutting out pink foam. I used a 1\/8 two flute 3″ long endmill, climb cutting at ~15K RPM and around 100 inches per min. That was probably far too slow, but I was going for a good surface finish, which I didn’t quite get\n<\/p>\n

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\nFoam before and after sanding, as you can see, it needed a lot of work.<\/i>\n<\/p>\n

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\nLaminating everything together.<\/i>\n<\/p>\n

\nLaminating everything together. I put some of the hardware in, anticipating that it would become difficult to work in the shroud once laminated. I was right, working on this heli is a real pain in the ass.\n<\/p>\n

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\nComplete quad minus electronics.<\/i>\n<\/p>\n

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\nQuadrotor with off the shelf electronics installed, ready for first test flights.<\/i>\n<\/p>\n

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\nMotor detail.<\/i>\n<\/p>\n

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\nElectronics mount flexure detail.<\/i>\n<\/p>\n

\nOf course there were problems… Some of them required fixing with green retaining compound (that stuff is awesome!). I also added a stiffening strap to try to keep the props from hitting the shroud.\n<\/p>\n

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\nQuadrotor with stiffing straps installed.<\/i>\n<\/p>\n

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\nStiffing straps installed.<\/i>\n<\/p>\n

\nThen it had to get light\n<\/p>\n

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\nCutting out some foam.<\/i>\n<\/p>\n

\nThen it had to get lighter still\n<\/p>\n

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\nFinal cut.<\/i>\n<\/p>\n

\nA few flights, then onwards to my own electronics. I aimed to simply replace the radio system. The electronics are still an active work in progress, hopefully I’ll finish it up over IAP.<\/p>\n","protected":false},"excerpt":{"rendered":"

Duplication of my final post for HTMAA. Grand overview of my final project and a few greatest hits. Teaser! Quick preview of my final project, but first some “greatest hits”. I put most of this work in the content repo, the pictures link to the respective project pages. FabISPkey FabISP remixed. I remixed the FabISP […]<\/p>\n","protected":false},"author":1,"featured_media":836,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"ngg_post_thumbnail":0,"footnotes":""},"categories":[8,27],"tags":[33,72,69,73],"_links":{"self":[{"href":"https:\/\/bardagjy.com\/index.php?rest_route=\/wp\/v2\/posts\/789"}],"collection":[{"href":"https:\/\/bardagjy.com\/index.php?rest_route=\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/bardagjy.com\/index.php?rest_route=\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/bardagjy.com\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/bardagjy.com\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=789"}],"version-history":[{"count":18,"href":"https:\/\/bardagjy.com\/index.php?rest_route=\/wp\/v2\/posts\/789\/revisions"}],"predecessor-version":[{"id":1087,"href":"https:\/\/bardagjy.com\/index.php?rest_route=\/wp\/v2\/posts\/789\/revisions\/1087"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/bardagjy.com\/index.php?rest_route=\/wp\/v2\/media\/836"}],"wp:attachment":[{"href":"https:\/\/bardagjy.com\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=789"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/bardagjy.com\/index.php?rest_route=%2Fwp%2Fv2%2Fcategories&post=789"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/bardagjy.com\/index.php?rest_route=%2Fwp%2Fv2%2Ftags&post=789"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}