How To Make a Brushless Motor for Education

Exploring electromagnetism with DIY laser cut motor

laser cut brushless motor

Teaching kids about how motors work can be a lot of fun, particularly when they get to build and experiment on the motors themselves. So when engineer Matt Venn spotted a neat little 3D printed motor, he decided to make his own variation – this time using laser cut components and an Arduino to run the show.

The learning experience

Once all the kinks were worked out, the Arduino was replaced by a few cheap electronic components. This way, students have the opportunity to build the entire setup from scratch, mounting the electronics on a breadboard as they work out exactly what each component does.

The adjustable laser cut rotor has slots to hold different numbers and configurations of magnets, and this can be further extended by cutting custom rotors to suit alternate magnet arrangements.

This is a great project that encourages a hands-on approach to exploring electromagnetism by building a simple DC brushless motor. Consideration has been made to come up with a laser cut solution that can be assembled and studied within the time constraints of a science class workshop.

Matt has provided all of the files and extra info you need to get the motor up and running on GitHub, where you will also find a brief video walkthrough that highlights how the motor and supporting circuitry work.

Matt Venn via Hackaday

Ideas for Creative Agencies & Brands – #28

A Vision for the New Year

The impact of Google Cardboard on the accessibility of virtual reality has been dramatic. While not quite in the same league as ‘true’ VR headsets such as Oculus or Sony’s offerings, it is remarkable what can be achieved using the Cardboard platform for under $10.

One benefit of the accessibility of Google Cardboard is that it is an ideal vehicle for promotional messaging. The platform has been used for advertising campaigns by some pretty big players, as well as a myriad of small-scale campaigns and personal projects.

What is Google Cardboard?

Watch the intro movie below to see how the New York Times introduce their viewer in a campaign that saw the units distributed to over 1 million subscribers. The portal at NYTVR showcases a collection of highly refined immersive clips filmed specifically for use in these virtual reality headsets.

 

The high tech approach to low tech

For a really polished example of Google Cardboard at its finest, look no further than the Volvo XC90 campaign. Using some serious high-tech equipment, they were able to film an immersive experience that enables people to get a sense of what it is like to be physically inside the new car. The Volvo Cardboard viewer has also received a fancy facelift, going beyond everyday cardboard to reflect the luxury feel of the brand.

 

Are you ready to go Virtual in the new year?

Can you think of a way to create your own branded laser cut Cardboard Viewer? Although the content associated with these two examples looks pretty slick, the physical platform itself is still based on the same core components. With freely available plans for the structure to be laser cut, it is surprisingly easy to achieve unique, engaging results from more modest materials and equipment.

If the examples from New York Times and Volvo have perked your interest, then you may enjoy looking further at how others have made use of this affordable technology. There were also some creative submissions to the Ponoko Cardboard Design competition, showing there is still plenty of room for clever adaptations and customizations. Let us know in the comments below how your company can use Google Cardboard to dazzle and delight your customers’ minds.

 

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Entrepreneur turning hobby into novelty toy and apparel company

Robots! Yeah!
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Imagine a community of robots; from helpers to dance masters to happy companions and more. What stories would they tell? What journeys would they embark on, as their world and ours merge into one fantastical creative adventure?

The characters from RoboMustache were created and designed by Charles Wade of Greensboro NC, and they are working their way into the hearts and imaginations of young robot enthusiasts one laser cut assembly kit at a time.

It all started with the Helper Bot

GREENSBORO, NC — After graduating from college, designer and maker, Charles Wade, began his hobby by making unique animal stickers, which later morphed into woodcraft and papercraft creations. During a test for one of his woodcrafts he designed and built a poseable wooden robot. The Helper Bot was born.

With the creation of the Helper Bot, Wade began experimenting with other ideas. After receiving feedback and appreciation for his work, he created more robots and designed assembly kits that would allow others to build his creations.

Resurrected from the scrapheap in a derelict factory

Wade has cultivated his hobby into a career by establishing RoboMustache; a collection of wooden robot assembly kits, accessories and merchandise. More than a collection of novelties, the RoboMustache hints at a rich world of storytelling as well. Coined from a found project in a derelict factory, as the company grows, so will the RoboMustache universe. The story will expand to tell more about the existing robots and bring in new robots along the way.

The most mustchioed  ‘Staff Pick’ on Kickstarter

Wade is crowdfunding the project to take the RoboMustache universe to the next level. The Kickstarter launched Dec. 4, 2015 and runs through the new year. Rewards for backers include assembly kits for each of the RoboMustache characters, laser cut in bamboo ply by Ponoko.

For more information on RoboMustache, visit RoboMustache.com or email contact@RoboMustache.com. To see the Kickstarter, visit RoboMustache.com/Kickstarter

Ironically Retro Laser Cut Time

Laser cut clocks, stars, and a small business!

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Above is an alarm clock housing for your smartphone. It is laser cut from MDF, like Ponoko.com‘s own, and comes from vincent.verheggan over at Instructables.

After the jump, stars, and a small business… (more…)

Bare Bones of Laser Cuting

Laser cut skulls, elephants, a broken clock, and some abstraction!

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Above are Calavera skull charm bracelets. They are laser cut and etched from mirrored acrylic like Ponoko.com‘s own and come from Guy Blanco.

After the jump, elephants, a broken clock, and some abstraction… (more…)

Share Your Google Cardboard Design Idea, Win Your Share of $250 Making Vouchers

We’ve giving away everything you need to create your own custom Google Cardboard

You’ve heard about Google’s VR viewer, you’ve seen the cool things it can do, and you know how to make one for less than $10 with Ponoko.

Wouldn’t it be cool to make one for FREE?

We’ve got 3 Google Cardboard Kits and over $250 worth of laser cutting that we’re giving away to folks with the best ideas for a custom Google Cardboard headset.

Google’s kit is based around making with cardboard, and the manufacturing specifications are open source. This makes it perfect for developing and prototyping your killer idea with laser cut parts from Ponoko.

Maybe one button isn’t enough for the game you’re developing. Maybe you want an oversized headset that works with your iPad. Maybe you just want a shiny gold acrylic VR headset to match your gold watch.

Whatever your idea is, we want to hear it. The folks with the best ideas will get a head start on making their ideas a reality with one of the following prizes:

1st Prize – Google Cardboard Hardware Kit + $150 Worth of Laser Cutting
2nd Prize – Google Cardboard Hardware Kit + $75 Worth of Laser Cutting
3rd Prize – Google Cardboard Hardware Kit + $35 Worth of Laser Cutting

How to Enter:

Simply describe your idea in the comments below. Include a mockup, sketch or other visual aid that shows what makes your idea great. Multiple submissions welcome.

About the Prizes:

Hardware kit includes everything you need to get started: Two 25mm diameter lenses, one ring neodymium magnet, one ceramic disk magnet and a set of sticky-back velcro strips. Free laser cutting is issued in the form of Ponoko Making Vouchers. The original Google Cardboard costs less $10 to make with Ponoko, so the $35 prize is more than enough for three iterations!

Judging Criteria:

Finalists will be selected using the following criteria, in no particular order:

  • Originality.
  • Interesting use of material(s).
  • Production feasibility and/or market appeal.

Submit your idea before next Friday, August 14th. The best ideas as voted by the Ponoko team will be announced on Monday August 17th.

Don’t hesitate to let us know if you have any questions, or things we can assist with.

Good luck!

Update 18 Aug: Congratulations to the winners!

First Prize – Richard for steampunk Cardboard

Second Prize – Tana for a Cardboard with a proximity sensor.

Third Prize – Kevin for a Cardboard stand that allows for time-lapse photos or other similar time consuming techniques.

If you are one of our winners, please check your email for details on how to claim your prize. Thanks again to everyone who participated!

Ponoko’s Google Cardboard Gives You Virtual Reality For < $10.

Virtual reality from Google, with laser cut parts from Ponoko

Google Cardboard is a virtual reality kit that starts with a simple viewer anyone can build or buy. It works by turning your phone into a virtual reality headset using a sheet of cardboard, two plastic lenses, a magnet and a bit of velcro.

Using laser cut parts from Ponoko, you can get started with Cardboard for less than $10.

So far there have been a ton of apps released for the platform including test drives, roller coaster rides, and mountain climbs. But it’s not just games and rides- People are finding new ways to use the kit – from campus tours to marriage proposals to vacation planning.

Anyone can build their own Google Cardboard – there are no official manufacturers and the whole kit is open source. Want to engrave a VR code that opens up your app? Go for it. Want to add custom branding? No problem. Want to design a shiny gold mirror headset? The sky’s the limit.

Since the kit is made up of inexpensive cardboard, it’s perfect for experimenting and creating your own version using laser cut parts from Ponoko.

To get you started, we’ve put together a handy instructable that walks you through how to laser cut your own Cardboard headset with Ponoko for less than $10.

Got an idea for your own custom-made Google Cardboard compatible headset? Let us know in the comments below!

The Most Advanced Peanut Butter Mixer Ever

Arduino-Controlled Peanut Butter Mixer from Mark Frauenfelder

Mark Frauenfelder has an awesome writeup of Ponoko over on Foundry – the show and tell site for makers.

If you’re a fan of peanut butter & jelly sandwiches, you’re familiar with the natural separation of oils that occurs after opening your jar of peanut-buttery goodness.

Made from laser cut bamboo from Ponoko – Mark’s Arduino-powered invention helps stirs the yummy ingredients back together for smooth spreading.

This ingenious tool not only helps solve the mess associated with mixing natural peanut butters, it’s a great example of what’s possible when you combine the precision of laser cutting with a bit of creativity.

You could say that ingenuity & laser cutting compliment each other like, well, peanut butter & jelly.

Laser Cut Play Time

Laser cut tables, boxes, crowns, vinyl organization, and a broken heart

Above is coffee table inspired by Minecraft. It is a take on the simple layered topo but adding the 8-bit pixelation for all the gamers out there. It comes from Martin Raynsford and there a complete run down on how to make it Kitronik. The materials that go into the project are MDF, birch plywood, and acrylic and all available from Ponoko.

After the jump, boxes, crowns, vinyl organization, and a broken heart… (more…)

Booboo – The Interlocking Bamboo Drone

Interlocking bamboo drones from Andy Shen

There’s a lot of buzz around Andy Shen’s drones – and it’s not just the hum of his multi-rotor quadcopters. Earlier this year Motherboard featured Andy’s drones in their coverage of the first ever drone dogfight.

Since then, Andy’s been hard at work on his latest drone, the Booboo. Made from laser cut bamboo, the Booboo’s lightweight frame can be assembled like a 3d puzzle without the need for any glue or hardware. This unique interlocking design makes assembly a snap, while keeping the total weight of the drone to a minimum.

Check out the video below to see the Booboo in action:

Andy got his start flying drones in 2012 as a way to take aerial photographs of bike races. As a professional photographer and an amateur bike racer, Andy was enthralled with the idea of shooting races from the air. Once he started flying, he immediately saw improvements he could make to the drones on the market, so he began designing drones of his own.

After creating his racing quadcopter from CNC’d carbon fiber – the Fast Forward – He got the idea of making laser cut drone frames from Bamboo. His first step was to get his hands on a laser cut sample:

“I was pleasantly surprised to find laser cut bamboo is way cheaper than CNCing G10 or carbon. It also might be pretty light. I measured its surface area by counting pixels in Photoshop, and comparing that to a sample piece I get 112 grams for the frame, which is right on par with carbon frames!”

Andy started work on the Booboo using Google Sketchup. “It helped to build it in a 3d program to make sure all the parts fit correctly.” Andy says, “It’s a great way to visualize things and catch mistakes.” After a night of feverishly designing, he submitted his designs to Ponoko, and had a working prototype in a few weeks.

Andy’s first prototype went through two months of iterations before being ready for production. Andy details his process of testing, flying, designing and iterating over on his blog. After four iterations and a handful of crashes, Andy was ready to put the Booboo into production.

To achieve the Booboo’s unique interlocking design, Andy needed just the right amount of control over his parts, while still having access to Ponoko’s designers when he needed them:

“On the one hand, I love being control: I place the order and I upload the drawings. I’m solely accountable for the accuracy of my order.” Andy says, “On the other hand, the tight tolerances of the job required human supervision, and I was well taken care of by the crew to ensure that the materials met my specifications. It was really the best of both worlds.”

Andy credits Ponoko Prime for helping him keep the costs of his final product down. “You can’t beat Prime” Andy says, “Prime brought my costs down and allowed me to offer the Booboo at the right price for my customers. The Booboo is only viable at a certain pricepoint, so without Ponoko and Prime it would never see production.”

I asked Andy which drones are his favorite, and where he likes to fly. “We have a few spots in the city” Andy says “and we also have a club out on Long Island for weekends. For pure speed I fly the Fast Forward, and if I want to zone out and feel like a bird I fly the Booboo.”

Andy’s advice for designers just starting out with their own product line? “There’s few things more gratifying than seeing your idea realized in a tangible object” Andy says “There’s tons of great tips on the Ponoko site, so read them all and go for it.”

You can read about all of Andy’s drones at shendrones.com, and you can get a drone of your own at Andy’s Shopify Site.

Inspired to create your own product line? Make it with Ponoko!