Mark Frauenfelder “Made By Hand” on Colbert Report

Last night Mark Frauenfelder, editor in chief of Make Magazine and editor of BoingBoing, was on Colbert Report promoting his new book Made By Hand (published by Portfolio/Penguin).    cover of Made By Hand, by Mark Frauenfelder

Its a fairly short interview (under 6min with intro) but fun to see.  Mark talks a bit about the joys of making things by hand, growing & raising animals, and demo’s a couple neat projects. One project is my friend and fellow Crasher Tod Kurt‘s TweetM – a wireless device that blinks its multi-colored LED when selected keywords are entered on Twitter.  Another is the world’s most useless machine – its only function is to turn itself off.   The book sounds like a great read – it doesnt have instructions (ala Make and Instructables) but rather tells the story behind the instructions, the why and experience of learning.

I’ve been planning to get a copy at Mark’s long-planned visit to CrashSpace but alas it is scheduled for Wed June 30th – I’ll be on Maui that day.  We have had two way video feeds from CrashSpace with other spaces (notably Singapore last night), and the usual uStream channel.  Perhaps we can get something set up from a semi-public area in Maui and have a Maui Makers gathering?  It would be about 5pm Maui time since the LA event starts at 8pm.  Interested?

Update June 15: Dangerous Minds posted longer interview with Mark (25min!).

Robots And Dinosaurs — A Hackerspace Documentary (Sydney)

Robots and Dinosaurs is a Sydney Australia hackerspace and recently a student filmmakers team made a sweet little documentary on the space. Its been covered over on Make:Online and on R&D’s own blog.  I’m including the YouTube embed here for easier viewing (and experience with embedding.)   Its a very nice short piece about the community of a hackerspace – what I’m hoping we can get at Maui Makers.  They do note that most spaces have an electronics focus.  While that will be a big part of Maui Makers, I am planning we will be more of a Fab Lab with additive (3d printing) and subtractive (cnc milling) manufacturing projects.  Over Memorial Weekend I attended the Tin Man Tech 4 Day Original Metalworking Intensive. on metal working. I’ll get a blog post on that up soon… shaping and welding sheet metal (Al & steel) is a lot of fun too!  Enjoy!!

Desktop 3D Printing – Makerbot, RepRap et al

One tech of the Fab Lab/Hackerspace is the 3D printer, where an object is created by adding successive layers of material. There are a wide range of materials used – from frosting and clay, to various plastics, ceramics and even metals. Professional 3D printers started back in late ’80s with 3D Systems Stereo Lithography, which uses a laser to harden layers of liquid plastic. Today there are multiple vendors selling machines (StratasysObjet, Z-Corp, Dimension), with various technologies (laser sintering powders, etc).  All of these start with a 3D computer model of the part, slice it up into layers and then draw the layers with or onto the medium.   Sometimes the medium is a homogenous layer on which the machine draws (eg laser sinter metal/plastic, laser plastic curing, etc.)   other times the machine extrudes the medium.  The part takes shape as successive layers are created.  Some tech allows for ‘support material’ that supports overhangs and small parts while higher layers are built. The support material is removed later using a solvent wash or mechanical means (cutting).

All those neat commercial machines cost a fair chunk of money.  The ‘low priced’ HP branded DesignJet sells for about $17,500 (in europe). High end machines run into the hundreds of thousands of dollars. Not what small shops can afford!! There are a variety of service companies (eg Shapeways, RAPID Tech HI) to which you can upload designs and they will send you completed parts.  There is at least one directory of such service companies Rapid Today to help locate one nearby. (RAPID Technologies is our closest in Honolulu.)

On the other hand, there is the whole world of DIY hackers.  The granddaddy of the DIY 3D Printer is the RepRap – self replicating rapid prototyper.  They are currently on their 2nd generation design (Mendel) and are completely free and open source.  All designs and software are downloadable from the web.  There are a variety of child projects such as Fab@Home and Makerbot CNC.   I own a Makerbot Cupcake CNC, known as Goldbot.  It was built during a 3 day ‘Make-In” at CrashSpace in December 2009.  It will be one of the first machines available at Maui Makers.  The advent of these DIY tinkerer boxes was recently reported by the LA Times in the May 29 “These ‘printers’ make 3-D stuff” by Nathan Olivarez-Giles.  The article opens with Jay Leno’s use of a commercial machine to create parts for his antique car collection, and then moves quickly on to Sean Bonner of CrashSpace and Bre Pretis from Makerbot.  It closes with a quote from yours truly!  It also includes photos from Nathan’s visit to CrashSpace.

GoldBot and friends, (Michael Robinson Chavez / Los Angeles Times / February 23, 2010)

At present I am not the best evangelist for DIY 3D Printers. The current batch are definitely a tinkerers machine.  They take a lot of care and fussing to get good consistent results.  Some people have lots of success and I know some who actually make commercial parts with their machines. Alas, I am not in that category.  Goldbot suffers from a common malady of Makerbots – poor plastic feed.  The Makerbot uses a plastic wire (ABS or PLA) that it pushes down into a heat chamber and out a nozzle (a Plastruder).  One of the common failure modes is for the drive wheel to fail to properly grip the wire and slip, stopping the feed.  There are several reasons this happens and the Makerbot designers are all over the problem.  The new MK5 Plastruder has a new drive wheel that can be used in a MK4 Plastruder.  This, along with the redesigned heater and barrel of the MK5 should greatly reduce errors.  I am looking forward to installing one on Goldbot later this year, after I complete the move to Maui.

Design of parts is also an issue for all 3d printing.  You need some type of 3D CAD program – and these can be very expensive.  There are low cost/free alternatives, such as Google SketchUp and Blender, but all of them carry a learning curve – sometimes its pretty steep, more of a learning cliff.  3D Scanners exist (including DIY ones!) that can scan an existing object to create a 3d model.  After creating the raw model, the objects must be converted to proper format for the 3D printer.  This includes cutting it in layers and designing the tool path (speeds, geometry, etc).   The Makerbot tool chain includes several alternatives that are free.  The primary tool is SkeinForge which is really more of a collection of tools that handle various steps in the process.  SkeinFox is a Mac OSX application that simplifies control of SkeinForge.  There are LOTS of parameters to consider – some of which make a big difference in printing success, others dont seem to have much effect at all.  It takes a fair bit of experience to know what to tweak.  Then again, I have been fairly successful using some of the pre-canned parameter sets.

3D Printing will be a feature of Maui Makers.  Goldbot will be available for tinkerers. I plan to get some more experience with it myself so I can help others learn about the process and create.  There will, in time, be a wiki page tree for using our 3D printer.  I’ll update this post with links then.

Maui Techies Dinner 4/29/10

Last night the Maui Techies from gathered for a dinner at Asian Star in Wailuku.  It was a nice venue – quiet, open and good food (Vietnamese) – but lacked WiFi.  I had never been to this part of the island before – its a more industrialized area with auto body shops, small business offices, etc.  Quite a contrast from the usual image of our island – but a welcome one.  We do have small industry here.

There were probably between 15-20 people there, with some leaving a bit early and some arriving fairly late.  I got there about 6:20 and found about 6 people at a big table. It was obvious who they were.  People trickled in for then next half hour as we ordered up some family style grub & drinks.  Reichart showed off his iPad and apps. We all ohh’d and ahhh’d and exchanged comments on John Stewart’s recent rant about Apple and Gizmodo… and views on development for apple platforms etc.  (btw check out Mr Jalopy’s rework of S. Job’s anti-flash statement) As more people came in the table filled up and conversation volume increased. I got lost in talking with Larry McCarty about education, Garrett Lisi about theoretical physics, etc.  After food I moved around a bit and met Doug Nelson and his wife Susan and a few more folks.

Susan was quite interesting.  She (and Doug) are involved with South Maui Sustainability, and she pointed me at the related Upcountry Sustainability group.  Both are working on projects to encourage sutainability (balancing human activity in our ecosystem for long term futures).  The South Maui site has a good thread on “What is Sustainability.”  As the owner of a couple acres in Ha’iku and a long time garden putterer (aside from being a hard core Geek), I look forward to exploring these in the future.  There are lots of opportunity for hacking and making in this area. Its a lot of what the Fab Labs around the world work on for local projects!

I am sure there will be many more meetings of the Maui Techies. You might consider signing up on TechHui. The site sends notices of forum updates, but doesnt include the text, forcing you to go to the web site to read them. I’ll try and post notices before hand here and maybe someday get a mail list working for maui makers.

More later – I’ve got carpet to rip out so we can paint and get flooring in before The Wife arrives.

23b Shop sign

Visit to 23b Shop in Fullerton, CA

On Saturday April 17, The hackerspace 23b Shop in Fullerton CA had an open house and giant birthday party for Amber.  I had read up on the space a while back and wanted to check them out, so I drove down mid-afternoon.  I should have checked sigalert before driving, as the I-5 had some serious delays and it wound up taking me almost 2.5hr to drive 70miles.  The space is tucked away in an alley of an industrial park, with little to distinguish it from the more commercial neighbors.   They do have a rather unique sign in their window…

23b Shop sign

Sign in window for 23b Shop - Dolphins with flamethrowers vs Unicorns with guns!!

Anyway, 23B Shop is different from many other places I’ve seen.  It was formed by a group of friends who wanted a place to hang out and setup their machines.  Unlike many hackerspaces, 23B has welding and machine tools in its inventory – perfect for making the odd killamajig and gunsmithing.  It s a fairly small space – about 1000 sq ft not including the ‘storage’ loft.  The most prominent feature is the UV curtained off welding area – those orange curtains do stand out!  It holds a small bench with Oxy/Acetylene, MIG and TIG welders.  Behind this are a good sized lathe, a Smithy mill, drill press, horizontal & vertical band saws, grinders, etc.  They have a sand blasting glove box chamber, and a kitchen oven modified for powder coating outsized objects.  They’ve also got a small electronics bench, and a foundry, etc.  Quite a bit to cram into a small space.  The space had a storage loft in the back when they moved in.  They scrounged up some cool honeycomb composite flooring and made it serviceable for people – creating a lounge with a couch, tables and small liquor cabinet upstairs along with the overflow storage.

View from doorway into 23b Shop

View from doorway into 23b Shop

Some of the machine tools on back wall

Another view of the machine tool corner

Electronics bench in back corner

The 23b Shop folks are true hackers of the old school.  They are long time attendees of Defcon and several are Security Goons.  These are definitely folks I’d prefer to have on my side.  They were quite a likable and friendly bunch.  They had set up a small inflatable pool in the drive way, complete with air bubbler – unfortunately using the bubbler kicked off the air compressor completely overwhelming any conversation.  They also had a decent outdoor dj/music rig setup complete with flashing lights.  I had to leave about 8:30pm, just as the party was getting rolling.   It was a good time and I enjoyed meeting the 23b Shop people.  They are welcome to visit us at Maui Makers – when we have a space!

23b Shop crew chillin outside

Chicks, rollerskates, automatic (airsoft) weapons and alcohol - Yeah! Thats Amber the b-day girl in green.

A Visit to NYC Resistor

A week ago I posted that I was going to visit NYCResistor and take a class on April 10 2010. Sorry it has taken a week to update but life intervened.

I took the subway out from midtown Manhattan where I was staying and arrived about a half hour early.  NYCResistor is located a short walk from the subway station in a non-descript brick building on a not too busy/not too quiet street. The doorway is barely marked and might be easily missed. Visitors may need to call to get the front door unlocked.  Once inside there is a cool LED light directing you up four flights of well worn wooden stairs to the space.  The space itself is has nice high ceilings and is HUGE.  I briefly visited their previous digs back in December and this new space is much bigger. They have a big open room up front for classes, a couple side offices (one is home to their Epilog laser cutter), and another even bigger room back through the arches that houses ongoing projects. There were a few folks working on projects in the back room when I arrived, and some others puttering about, doing improvements on the space, etc.  The coolest project in this back room at the time I visited was a pair of Makerbot Plastruder Mark 5 prototypes undergoing stress tests.  Zach et al had set up a pair of laser cut acrylic boxes into which the plastuders were oozing out a steady stream of black ABS plastic.  I got to meet Zach briefly – quite a pleasure for me, he (like the rest of the folks there) was friendly and fun to chat with.  He said the plastruders had been running continuously for 24-48+hours!  That beats the heck out of the 20 min or so I get out of the Mark 4 on Goldbot (my Makerbot Cupcake).  They still have some issues to work out but I am excited to see this development.

Front Room of NYCResistor

I was at NYCResistor to take Shelby Arnold’s class in Paper Engineering.  Basically this is paper folding to make popup cards and books.  Shelby passed around a nice tutorial book – Elements of Pop up: A Pop Up Book For Aspiring Paper Engineers. It is loaded with how-tos and examples. I ordered myself  a copy from amazon after the class. Shelby then showed us how to make a number of basic popups for simple cards. I made a half dozen or so in the hour+ of the class.  Mine were plain white with no decorations – simple engineering prototypes.  Others in the class (about 14 total) were much more artistic – tacking on decorative flourishes.  One person even made a pair of popup cards showing robots walking in a city – second card showed the flaming aftermath.  It was a fun introduction to the craft. I wish there was time to go deeper and try out their CraftRobo machine, but alas there wasnt time. (also the machine was not set up.)  I’ll just have to wait till I have some time to experiment on my own.

Simple popup card I made during class

After the Paper Engineering class, Raphael Abrams was teaching a Soft Circuit class.  It was listed as sold out so I had not pre-registered. It was also scheduled to end about 5:30 which I initially thought would be too late for me to make it back to Manhattan for the party my wife was expecting me to attend.  However, Raphael said he would gladly let me take the class for cash payment and since subway travel was quick, I dropped $30.  It was quite fun although it ran long and I had to bug out well before the end.  Raphael had us make a simple LED circuit with a battery pouch.  The conductive thread is really hard to work with. You need to cut it with a sharp knife to avoid any dangling bits that could cause shorts, etc. It is fat and not easy to thread into a needle (dang these aging eyes!), and then easily slips out.  It also tangles and knots itself quite easily so hand sewing is tricky.  I did manage to get a pair of white LEDs wired up properly (in parallel).  Raphael had some conductive tape which I put down over a coil of thread on one end of the circuit. The other end was attached to half of a metal snap that I sewed onto a small piece of felt that was then attached over the tape creating a pocket. Inserting the battery into the pocket in the correct orientation closed the circuit and lights up the LEDs.  Raphael had some more advanced projects planned, but by the time I got mine working, it was 5:45 and I had to bug out for the train. I wish I had stayed longer – the party was delayed an hour!  I am looking forward to working with more soft circuits in the future.  There is talk CrashSpace might host a class, which would be great… if I’m still here on mainland.  Otherwise, we will have to do ourselves in Maui!

Soft Circuit class at NYCResistor

My simple LED soft circuit works! Next step is to add the battery pocket.

My simple LED soft circuit - before battery pocket.

DIY Paper Engineering, Die/Vinyl cutters

I’m traveling on the mainland this week. Just spent a couple daze in Salt Lake City and off to NYC tomorrow.  Mostly this trip is for family purposes but on Saturday I’m going to be at NYCResistor taking a class in DIY Paper Engineering.  I am jazzed to be able to take a class at this hackerspace – both to learn paper engineering and to check out a class at an established hackerspace.  The topic came to my attention back when I posted to the Google for Maui discussion.  I later found a really cool post/video on Tangible learning in 21st century Digging a bit further I found the author Shaunna Smith is at U. Houston and giving a tutorial about this on Society for Information Technology & Teacher Education (SITE) on this (link to preview).  Both of these talk about using a computer die cutting system like the Craft Robo and Silhouette both of which are under $300.  NYC Resistor has one (more?) of these and I’m thinking it would be a really inexpensive bit of hardware for MauiMakers.  I’ll post more after the class and let you know.

Btw, I’ll be on island tween April 23-30 and would love to get together with folks.  Drop me an email if you want to suggest a time/place.

jerry at mauimakers dot com

Desktop Fab, Basic Machining and CNC

Desktop fabrication, as discussed in Gersenfeld’s book (Fab: The Coming Revolution on your desktop), and the related Fab Labs pretty much stick to the new small devices – laser cutters, small CNC routers, etc. However manufacturing has long used computers for fabrication on larger machines. CNC (Computer Numeric Control) has been around for a few decades, with Numeric Control predating it by a few more. The underlying machines (lathes, mills, etc) have been around for quite a bit longer.

As I got started on my path to Maui Makers in ernest last summer, I found a local adult school here in So Cal had classes in welding, basic machinist and CNC operation/programming. The welding class is highly regarded and has a 6mo waiting list. I put my name on the list and then turned to the CNC classes. The school (Simi Valley Adult School) requires new students to start with the Basic Machinist class unless they have significant experience and can test out of the class. Since I had minimal experience, I signed up and started the class. It was a great experience learning to use a metal lathe, surface grinder, vertical milling machine, etc. The class has print reading and math components as well as hands on creation of 8 projects. The projects lead you through the basics of using the machines -turning, boring, drilling, milling, tapping, threading, tapers, etc. The print reading was pretty simple for me – thanks to that drafting class way back in high school, before the age of CAD.

The math was very basic review… Odd tidbit here. The instructor (Oygar, great guy) told me american students have a much easier time with the math than europeans and others who grow up with the metric system. Much of the math involves fractions – basic add/subtract/multiply/divide, as well as conversion to/from decimals. This is very important when using SAE/English measurements (inches, feet), since those regularly use 1/4, 1/32, 1/64 etc. People in metric based countries apparently dont do a lot of work with fractions in regular schooling. Anyway, i had no problems with the math portion.

The Basic Machinist section took me a bit over 6 calendar months to complete, mostly because I took off from mid-Nov till end of January. It was very instructive and FUN to learn the bridgeport mill and metal lathes. I got clothes reeking of machine oil now, and a few more scars on my hands. It was a lot of good fun – and I developed a whole new level of respect and understanding of the basic manufacturing biz. Now I’m on to the CNC class – which is pretty trivial basic cartesian coords plus manually creating G-code to run the big Haas CNC machines the facility has. Manually writing cnc code is a pain and nearly archaic approach since there are lots of good CAD/CAM tools that eliminate the need to work in the machine code. However, just like knowing computer assembler (machine code) is (IMHO) essential for software engineers to understand the computer, it is important for CAM designers to understand.  I’ve also been learning g-code as my Makerbot runs on it. The Haas has a much more elaborate set of commands it understands, but essentially its all g-code. pretty cool.

I’ve also started the welding class at SVAS. I think these basic manufacturing skills are essential and am considering including a mill and lathe in the equipment I put in my workshop.  There are some nice small CNC bots as noted on the CrashSpace wiki.  Having one of these would be a great compliment to a laser cutter. A big Haas CNC would be nice, but they are quite a bit more expensive!

Google Fiber for Maui – Digital Fabrication, Fab Lab, Physical Computing, Hackerspaces

Here is some preliminary prose I wrote for the Google Fiber For Maui initiative. It could also be considered the seeds of a business plan for Maui Makers.

The benefits of broadband are not limited to online experiences. Digital fabrication and physical computing are two areas that draw on internet connections, especially when combined with social interaction and education.

Digital Fabrication combines computing and manufacturing technologies to create physical objects directly from computer models. Tools include laser /plasma/water cutters, CNC (Computer Numeric Controlled) mills/lathes, 3D Printers (aka Rapid Prototypers), and electronics workstations.

Physical Computing refers to the use of sensors and actuators with micro-controllers to interact with the physical world, and especially people. It is often used as a way to teach computing technologies to non-engineers such as artists, architects, and designers.

Fab Labs are small scale, high tech workshops providing the basic digital fabrication tools to “make almost anything” (furniture, electronics, replacement parts, etc). While Fab Labs began at MIT’s Center for Bits and Atoms, they have expanded to over 40 locations in over 16 countries. MIT is now developing the Fab Academy program to provide instruction and supervision to Fab Labs around the world, using video collaboration and lectures from global faculty. Combining local facilities with remote instructors creates distributed rather than distance education.

Yet Fab Labs are a large scale, academic enterprise, requiring tens of thousands of dollars of capital investment, often requiring support of an established college. Hackerspaces are an alternative form of collaboration and education in digital fabrication and computing arising from a community of interested people – sometimes known as Makers. There are hundreds of such spaces around the world. They meet in local spaces, sharing ideas, projects, tools, and often collaborate with other spaces.

Makers at hackerspaces, fab labs and independently use the net to collaborate and share. Sites such as Thingiverse, Instructables, WonderHowTo, VideoJug provide archives of instructional videos and downloadable designs. Make Magazine has its web with very active blog and a growing list of local Maker Faires, where people come together to share their creations.

A community connected with broadband fiber, and a center for digital fabrication could provide an official Fab Academy, as well as an active contributing member of the international Hackerspace and Maker communities.

A Maui based, broadband supported, fab center would also provide an excellent host for workshops and conferences. Maui already is a prime destination for vacations and conferences, with excellent resources such as hotels, excursions, family activities, etc.