Category Archives: Greencastle’s Makerspace

Making A Custom Bracket

Nomad CNC machining setup at Castlemakers.
Machining the aluminum bracket on our Nomad 883. You can see videos of the CNC in action on our Youtube channel.

We’re certainly excited about the new electronic equipment capability at Castlemakers, but the makerspace is not just electronics. One of our members, Dan, asked about making a bracket for his 2009 Triumph motorcycle to install an upgraded combination gauge for the stock speedometer & tachometer. We’ve only done a little aluminum machining, and it can be a very slow process, but if you don’t try you’ll never learn what you can do!

Close-up of aluminum bracket being machined on CNC.
Aluminum plate machining into a bracket.

The original gauge included some warning lights, which he wanted, but weren’t part of the upgraded combo gauge so they were purchased separately. So Dan needed to create a new bracket design to hold the new gauge and lights.

Finished Triumph bracket Installed on the motorcycle.
Finished Triumph bracket.

I’ll let Dan take it from here:
“I used Adobe illustrator to make a vector file of the shape I wanted, along with holes for mounting the bracket and indicator lights. I made a prototype on the laser cutter, and after a few small adjustments, we made the final version out of 3mm thick aluminum with the Nomad desktop CNC. There are still a few little tweaks I might make to get the spacing perfect (I ended up having to hand-drill one more hole for a button I had forgotten about), but I’m happy with the result. Couldn’t have done it without Castlemakers!”

Start of a New Year

3D printed round tuit
Multi-color Round Tuits designed in January 3D printing by class attendee David.

It’s exciting to be able to offer classes again, even though with a reduced size and constraints due to Covid. Introduction to 3D Printing will be offered on January 23rd at 1 pm and our popular Introduction to Laser Cutting/Engraving on February 20th. We’re hoping there’s also interest in some micro:bit classes, refer to our classes page for more information.

We’ve continued to experiment, a lot, with the micro:bit since giving them away to youth in the fall of 2019. The micro:bit capability is still impressive for a device that size. In the window of our Franklin Street location you can see several micro:bit projects, including some that have been written about before.

Window micro:bit that remotely flashes lights & rings an alarm bell!

One of the more mysterious window projects uses the micro:bit’s internal bluetooth radio. There’s been a micro:bit for some time that sends scrolling text and can control a string of lights and a rather loud alarm bell if the right text is sent wirelessly from another micro:bit to the window unit.

Hint: the words to send are obvious, it’s easy to program in MakeCode, and use Radio Set Group 1. It even works from outside! I’ll link later to some more detailed additional help.

Holiday Making

Acrylic Prototype ornament
Prototype green acrylic ornament.

This year we decided to pitch in and help Main Street Greencastle’s Santa in the Park project by making holiday ornaments to give away in Santa’s gift bags. We’ve held classes in making holiday ornaments before, so it seemed like a natural fit with one big difference. Instead of making 5-10 ornaments designed by class attendees, we needed to make 500 ornaments for the gift bags in 2 weeks or less!

Laser cut holiday ornament
Closeup of the final laser cut wood ornament design .

3D printing the ornaments, which we’ve done in our classes, was out due to the time constraint. Recently I helped a local entrepreneur make his parts for a new product idea on our laser, creating a little over 150 pieces in 15 minutes. They needed to be extremely precise and were slightly smaller than ornaments, but that had me thinking this was the way to go. What we needed was a simple to engrave & cut design that could be done in a reasonable length of time.

Finished laser cut Castlemakers holiday ornaments.
Getting first batch of holiday ornaments ready for delivery.

A local high school student, Hyrum Hale, came up with design that with a few modifications we could use. Our first prototype in green acrylic looked nice but wasn’t really visible on a tree, plus enough acrylic was hard to find due to Covid. Getting it to engrave/cut quickly required additional work; size of the ornament, material choice & availability, laser settings, and laser bed calibration/set up all were factors that determined time per ornament, quality, and repeatability. Making 500 items of anything means you learn a lot!

Although the cutting/engraving time was still substantial, we made the deadline and are really excited for our first time doing this. There’s a few extras at the Makerspace if you’d like one. We’re also already thinking about a new design for next year…

3D Printing with Scrap

CD3D 3D Printer made with scrap parts
Ian’s new 3D printer made with scrap parts.

One of our more prolific makers, Ian Girvan, recently created a 3D printer using mostly scrap parts found at home and at Castlemakers. It’s impressive, using old computer CD-ROM and DVD drives for their stepper motors and mechanisms along with a second hand computer power supply.

What a great way to learn about 3D printers, brings to mind how the first consumer level 3D printers were created in the early days of the RepRap movement. I’ve been watching in awe the last few months as he figured out how to make the old parts work, only buying a very few new items like the hot end. He’s detailed some of his work for us on this webpage, it’s definitely worth a look!

Makerspace Improvements

Shapeoko parts before assembly.
Parts that we received to build our latest CNC addition.

With the Covid-19 virus slowing down our activities, we’ve used the time to make some additions and upgrades at Castlemakers. Plus catch up with some of the work it takes to keep an all volunteer, non-profit makerspace running.

One of the more exciting additions has been a larger Computer Numerical Control (CNC) machine, a Shapeoko XXL. CNC’s have been used in manufacturing for years to make things in factories. More recently, like 3D Printing, the design, control, and cost of CNC machines has gotten to the point where desktop units are feasible. Although our latest addition is awfully big for a desktop with a 3.5×4’ (1×1.2 m) footprint! 

Shapeoko XXL Assembled with t-tracks and first test part.
Assembled CNC after cutting first test part with v-groove end mill. Red dust hose adapter was 3D printed at Castlemakers.

Prepping the room downstairs has taken some time, including improving electrical, airflow/dust control, and creating a big sturdy table to hold the unit when cutting/machining things. After cutting our first piece on it, the potential is very exciting. Most folks will use it for wood and plastic materials, but the rigidity, precision, and end mill rotating speeds makes metal possible. There’s already at least one member who’s planning to make guitar bodies our new one. And of course we’ll be offering community classes once we can start those again.

One Person’s Trash…

Imported CNC table and parallel controller.
CNC table and controller that was given to the Makerspace.

We’re given a lot of different things at Castlemakers, from old scrap electronics to tools, often so they don’t go to waste or for kids to tear down and learn… and maybe a few adults. Sometimes we can even retrofit the parts into something more current.

Desktop CNC controlled by arduino via USB.
The mini-CNC now uses an Arduino/GRBL based USB to parallel port interface so it can use standard G-code.

In March, Sam Williams of Cloverdale, who had brought his son to our CoderDojo, dropped off a box of parts that included a no-name, imported desktop CNC that hadn’t been run in several years. Where he works, a Terre Haute CNC shop, several folks had bought a few to learn CNCing. He no longer used his so gave it to us for parts or to use. It was an older model that used a parallel printer port and special control box on a Windows XP machine he also gave us.

3D printed case for the Arduino GRBL shield. There is also a print-in-place button in the upper left corner of the case.
Arduino GRBL shield with 3D printed case Ian designed. Captive reset pushbutton is at the upper left corner.

One of our members, Ian, decided to get it running. By using an Arduino and a $15 controller shield, he’s been able to get it machining using a laptop and free open source software via a USB port – a big improvement! He even designed and 3D printed a case which has a print-in-place button to press the onboard reset button.

You can see it if you look at the table through our front window; adding limit switches is the next addition. After that we’ll put it in the front window on Franklin St. for a while before using it in classes, it’s a pretty good machine to learn about CNC’s.

What happens at Castlemakers

We often get questions about when to visit Castlemakers; the best place to start is our events webpage. You can drop in during Open Shop or also attend one of the events listed.

4th Graders from North Putnam learn coding on a micro:bit
Putnam County Kids Count catapult design testing with fruit, candy and marshmallows.
Kids test their designs with different size & weight projectiles.

For people not familiar with makerspaces, they may not realize everything going on. For example, limited ‘retail’ hours (what we and other makerspaces often call Open Shop time) reflect the volunteer nature of them. There are lots of passionate people and activities going on outside those times, often working individually and with other organizations.

Attaching bridal to tetrahedral kite before testing at Putnam County Kids Count.
Two teams combined efforts to build a 10 cell tetrahedral kite.

For example, in the last 2 months Castlemakers worked on a number of youth-oriented events not listed on the webpage or on social media. Just a few weeks ago we were out at Heritage Lake working with over 50 kids at Putnam County Kids Count helping younger kids build and test catapults, then the older ones build and fly tetrahedral kites!

Another outreach event involved 2 other organizations in early May: Castle Arts and Putnam County 4H. Thirty North Putnam School Corporation 4th graders came to downtown Greencastle to learn about computer coding. While one group learned and used a robot at the 4H office to sort and count chips, the other group was at the Makerspace.

This robot was coded to put each color chip in a different bin.

Christian Destremps did a fabulous job teaching them algorithms/coding around the corner at the 4H office using Lego EV3 kits built into a color chip sorting robot. Castlemakers helped with assembling his robot design and 3D printing bins to catch the different colored chips.

Learning how G-code is used in 3D printing.

At the Makerspace we showed them how coding is used in 3D printing, laser cutter/engraving, and CNC machines. One section saw the coding (G-code) in action with our makerspace fabrication tools. At the same time the other section programmed a micro:bit, a small micro-computer board, using a block-based coding editor.

It really demonstrates what can happen in our community when different organizations pool their resources together. You’ll be hearing a lot more about the micro:bit board in the next few months here in Putnam County.

Greencastle First Friday Events

With this month's Laua theme we had a palm tree & create-your-own Tiki head out front.
First Friday project to color/create a Tiki head out in front of Castlemakers.

Our downtown location gives us a great opportunity each month to participate in Main Street Greencastle’s First Friday. Each month we not only have ‘open shop’ to share what’s going on inside the Makerspace, but also try to have some themed making events that folks can see / participate in.

This month Main Street was promoting a luau theme – so making a carpet tube palm tree and some Tiki heads were naturals. The Moai head printed on our Rostock Max 3D printer inside was so big that it took nearly 11 hours to finish; although started at noon I’m fairly sure no one else saw the finished print Friday night.

Moai Head printed on delta 3D printer.
Moai head print that is over 35 cm (14″) tall.

Then there was the ukulele playing Lego Mindstorm robot that Jacob built for the event. Thanks to Putnam County 4H we’ve had some EV3 robotic kits on loan for a while, using them in our CoderDojo, projects like our PuttCode, and getting kids & adults interested in robotics.

Thanks to Jacob & the rest of the Hale family for helping out – not only the things they made but with running this great family oriented monthly event.

Photogrammetry and 3D Printing

roman lamp made using photogrammetry
Image of a Roman lamp unearthed this summer in Italy created from photos & then 3D printed.

Castlemakers offered our first class on photogrammetry, or using photographs to create 3D objects, in October. But the more interesting story to me was how we got there. It began just before our Intro to 3D Printing class last spring, when a couple of folks wanted to learn about 3D printing so they could hopefully print things from an archeological dig in Italy in the summer. While I had experimented some with earlier software, this was mostly new territory.

Italian dig site near Umbria being printed. Pillars are the flooring in a Roman bath house.
Italian dig site near Umbria being printed. Pillars are the flooring in a Roman bath house.

But Rebecca, one of the students in the class, took it to another level. She was able to get a copy of a professional program, Agisoft, then take pictures at a Roman dig site in Italy this last summer. Using the program, she generated 3D images of artifacts they found and even took photos of the excavation at the site (a Roman bath house) which she was able to turn into a 3D image. When she got back in August, in a little over a week she was able to 3D print not only artifacts but also make a model of the dig site using the 3D printers at Castlemakers.

As we prepared for the Castlemakers class to show others how to do it, we discovered what may be an even better solution – a program called 3D Zephyr. We decided to cover both, especially since 3D Zephyr has a way of extracting photos from video to make the 3D image – a pretty amazing feature! The experiments will continue with local landmarks and we’ll be doing the class again this spring.

Putt Putnam County Wrapup

Putt-Putnam-FranklinOur 3rd Annual Putt Putnam County, held on Main Street Greencastle’s October First Friday, became our largest yet. This year anyone in the area was encouraged to create/build a mini-golf hole for everyone to play. The end result: we ended up with a course that ran from Indiana Street down Franklin to Vine Street!

The community built mini-golf holes really added to the diversity, from the Kirsch Dental chomping teeth to South Putnam School Corporation’s football hole. It also included an impressive arduino-powered hole from Tenzer Center and Wasser Brewing’s final hole led up to their outdoor serving area & music.

Putt-Putnam-NightAnd of course the Castlemakers built holes were impressive as always with a Skee golf-ball hole,  mini-golf bowling alley, Horcrux hole, and a Candyland hole that had a chocolate river (maybe using chocolate pudding was a bad idea). But will cover those and the other mini-golf holes in a later post.

Special thanks to all the organizations that brought mini-golf holes and Main Street Greencastle for helping with the city to block off Franklin Street for us. It’s not too early to start thinking about an entry for the 4th Annual Putt Putnam County in October 2019!