10 Amazing Tools

Long before humans evolved into Homo sapiens, tools were already in use. Over time, these tools evolved into increasingly sophisticated versions. Today, tools like those used to build prototypes for groundbreaking products are so complex and impressive that most of us will never own them. However, for those pushing the boundaries of innovation, these tools are essential.

One fascinating prototype built using the tools we'll explore in the following pages is the revolving circular waterslide shown above. The team from Discovery's "Prototype This!" also attempted to build a 6x6 all-terrain vehicle and robots designed for boxing. The "Prototype This!" team consists of five scientists and engineers from diverse fields such as animatronics, mechanical engineering, and electronics. Together, they work on creating mind-blowing futuristic prototypes in a short time frame.

Unlike the forgotten tools gathering dust in your garage, these cutting-edge tools are key to advancing human creativity and developing groundbreaking new products. In the upcoming pages, we will delve into some of the tools featured on "Prototype This!" and the fascinating roles they play.

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10. ZPrinter 450 3D Printer

While traditional 2D printers have become a standard in everyday life, 3D printers still manage to capture attention. Whether you're an architect, artist, educator, or product designer, a 3D printer could be exactly what you need.

The technology behind 3D printing shares some similarities with 2D printing, as both rely on software to break down 3D models into 2D layers or cross sections of the desired object. There are various techniques for 3D printing, but most involve layering materials. For example, in one method, fine powder layers are applied to the growing model, followed by a liquid binder layer. Once the object is printed, it can be coated with a sealant for added strength. Many components in a 3D printer are similar to those in a regular printer, but the technologies differ in important ways.

One major downside of 3D printers, when compared to their 2D counterparts, is that they tend to be slower. While some are quicker than others — the Z Corporation, for example, produces one of the faster models — even these only manage to print about one to two inches per hour, depending on the size and shape of the object being created. The ZPrinter 450, for instance, prints layers between 0.0035 and 0.0040 inches thick (0.089 to 0.102 millimeters) and can generate prototypes up to 8 inches by 10 inches by 8 inches (20 by 25 by 20 cm). Z Corporation also offers another model, the Spectrum Z510, which can create slightly larger prototypes with higher resolution, and at roughly the same speed as the 450. The ZPrinter is priced at approximately $45,000, while the Spectrum Z510 comes in at around $73,000 [source: Prototype Magazine, Prototype Magazine].

Despite the potential drawbacks — including the steep price — the possibilities of a 3D ZPrinter are certainly worth considering. You could print ocean floor relief maps, prototype products for pitches, model human hearts for research, or create architectural models to give construction teams a clearer visual representation of the design. And the best part? It’s all in full color.

The materials used in the 3D printing process can be varied to produce different characteristics in the finished product, such as making it more rubbery. Different companies employ a variety of techniques and materials, each affecting the end result in unique ways. Some methods create stronger prototypes, others provide more vibrant color results, and some offer greater precision.

On the following page, we will delve into the cutting-edge software that powers 3D printing technology.

9. SolidWorks 3D CAD Software

To create a 3-D prototype, the first step is to build a 3-D model. With the help of specialized software, you can create virtual designs that are then sent to a 3-D printer, turning them into a physical representation of your product.

CAD (computer-aided design) software was introduced in the early 1960s and became widely adopted in the 1970s. Since then, engineers and designers from various fields have used this technology to design everything from aircraft engines to household items like sinks.

SolidWorks is a leading provider of advanced mechanical CAD software, offering a wide range of tools for designing, editing, compiling, testing, and evaluating potential products. The software allows users to convert 2-D designs to 3-D, employ various tools to quickly and effectively develop their designs, simulate prototype assembly and function, and easily compare and share the final product.

Using SolidWorks software, you can do more than just edit 2-D images or create production-ready drawings. It also enables you to generate detailed 3-D image maps, which can be sent to 3-D printers to produce a prototype of your design in minutes (or hours, depending on its size).

A noteworthy example of how SolidWorks 3-D CAD software is applied comes from the MAKO Surgical Group. They created the MAKO Tactile Guidance System, a robotic arm designed to assist surgeons in performing more precise and less invasive surgeries. The system not only helps guide the surgeon’s hand, but also provides feedback on safe and appropriate cutting areas. SolidWorks was essential not only in designing the parts but also in creating the virtual map that guides surgeons during their procedures.

While the team on 'Prototype This!' isn't designing medical equipment, they do use a variety of tools to create their one-of-a-kind prototypes. Learn more about one of their go-to tools in the next section.

8. Fluke Multimeter

If you're involved in electronics or electrical systems, you’ve probably encountered a multimeter. For those who aren't familiar, a multimeter is a versatile tool that measures various electrical parameters. These can include connectivity, frequency, current, resistance, voltage, amperage, resistance, temperature, and more.

A multimeter is useful in many situations, such as testing for electrical currents, determining the resistance value of a component, or checking the charge level of a battery. These actions help identify malfunctions, solve problems, and play an important role in ensuring safety precautions are met.

Now, let’s focus on one popular multimeter brand – Fluke. Fluke offers a wide range of multimeters, each designed to meet different needs. Their more advanced models feature large, illuminated digital screens that allow users to view data trends with graphs and charts. This feature is especially helpful when troubleshooting intermittent electrical issues. More basic versions are available for simpler tasks. Newer Fluke multimeters come with large memory capacities and longer battery lives, making them ideal for continuous monitoring. Many of these models are designed for use in tough industrial settings, making them perfect for troubleshooting in hazardous environments like factories or engineering plants.

Whether you’re repairing a conveyor system, constructing a robot, or testing a fuse, a multimeter can be the perfect tool to ensure the job is done safely and efficiently. On the following page, we’ll dive into a similar tool that offers a different set of important functions.

7. InfiniiVision MSO7104A Oscilloscope

Oscilloscopes are similar to multimeters, but in many cases, they offer more power and elevate measurements and analysis to a new level. A key difference is that oscilloscopes are dedicated to electrical signals and, when we say dedicated, we mean that they allow users to directly observe the signals they are monitoring.

Oscilloscopes are an essential tool for designing and testing anything related to electronics and electrical systems. Used across diverse industries, you can find them in aerospace-defense testing facilities, automotive factories, and various research labs. By displaying the waveform of an electrical signal, they help determine if the signal is appropriate in both pattern and strength.

Agilent Technologies is one company that produces oscilloscopes. While their premium models can cost over $100,000, they also offer more affordable versions [source: Agilent Technologies]. Let’s dive deeper into what one of their more budget-friendly oscilloscopes can achieve.

The InfiniiVision MSO7104A Oscilloscope, priced at around $18,000, measures various characteristics of electrical waves in a 1 gigahertz bandwidth range [source: Agilent Technologies]. It provides high-accuracy measurements and can perform several mathematical functions to manipulate and analyze the data. With four analog channels and 16 digital channels, it allows users to view and compare different signals on its 12.1-inch screen. The oscilloscope can handle wave inputs at a rate of 4 giga-samples per second, with a refresh rate of up to 100,000 waveforms per second, delivering exceptional detail and accuracy. The InfiniiVision also boasts substantial memory, enabling users to record and playback sample signals for detailed comparison and analysis.

After exploring some impressive design and testing tools, it’s time to turn our attention to the factory floor.

6. VersaLASER VLS6.60

Laser engraving machines, which are also called laser etching machines, laser cutters, and a variety of other names, have become increasingly popular. This rise in popularity is due to their precise results and impressive speed. In the process, a laser beam is programmed to carve designs onto a variety of materials, whether organic (such as paper, wood, rubber, leather, or stone) or man-made (like plastic and metal). Lasers leave behind smooth, polished edges as they vaporize or cut through portions of the material following the designated pattern.

Laser engravers are versatile machines, capable of performing tasks such as cutting, engraving, scribing, drilling, marking, and various other modeling techniques. They're used to etch or imprint designs onto a wide range of items, from picture frames and trophies to circuit boards and jewelry. These machines are also useful in industrial environments, where they can assist in mass production, prototype creation, or other stages of manufacturing.

The VersaLASER VLS0 is a multi-functional laser cutter that can shape, etch, scribe, and cut objects in a workspace measuring 24 by 12 inches (about 61 by 31 centimeters). Weighing between 110 to 123 pounds (50 to 56 kilograms), this precise and adaptable machine requires its own dedicated computer, running on either Windows XP or Windows Vista. It also needs an exhaust system. While the cost of running the laser engraver isn't very high, purchasing the VersaLASER is a significant investment. The machine is also equipped with a cylindrical axis to enable 360-degree engraving.

A simple way to grasp the concept of laser engravers is to compare them to printers. Instead of adding material to a surface, these machines work by removing it to create intricate designs. Let's explore a similar machine on the next page.

5. Tormach PCNC 1100 Mill

A CNC machine, which stands for Computer Numerical Control, is an advanced, computerized device that takes the place of traditional workshop tools. These machines can perform a variety of tasks such as drilling, milling, and turning — all by themselves, creating the shapes that have been pre-programmed into them.

CNC machines are programmed to handle tasks that would normally require manual operation, as well as jobs that humans are incapable of doing. Whether it’s making intricate cuts in a heavy steel sheet or engraving a delicate image on the back of a gold watch, CNC machines can execute these tasks faster and with higher precision than any manual tool. Moving along multiple linear and rotary axes, CNCs can take on complex tasks, with more axes providing greater versatility and the ability to create more intricate shapes.

A standout CNC machine, the Tormach PCNC 1100 Mill (standing for personal computer numerical control), is a top choice for engineers, entrepreneurs, and hobbyists alike. This powerful machine can cut through materials ranging from wood and plastic to steel, iron, titanium, and chromium alloys, crafting them into any 3D design you need. The PCNC’s 1.5 horsepower spindle operates at speeds between 100 and 5,000 RPM.

If you want the full package, the PCNC 1100 Mill and its accompanying accessories will cost you around $16,000 [source: Tormach]. This price includes the base machine, which costs $7,480, and offers the flexibility to choose your additional components. Tormach worked hard during development to ensure that this personal CNC machine remains both affordable and user-friendly.

On the following page, you’ll find another tool that’s part of the "Prototype This!" team’s arsenal.

4. PS-900 Soldering System

When two metal surfaces need to be fused but can't be melted, a soldering iron is your tool of choice. Soldering relies on the principle that different metals melt at different temperatures, utilizing an alloy with a lower melting point to bond the metals.

Soldering can be a tricky task. Achieving the perfect balance of heat and solder is essential, especially when working with high-heat solder like many lead-free types. There's also the challenge of wetting, flux application, and the risk of not creating a strong enough bond. Mastering soldering involves careful consideration of all these factors.

To help with these challenges, many companies design tools to make the soldering process more efficient. OK International, for example, offers a range of products for electronics assembly, including their PS-900 Soldering Station.

The PS-900 features SmartHeat Technology, which ensures precise and consistent heat during soldering until the iron is placed in the auto-sleep workstand. It's perfect for lead-free alloys, and the company provides various tips to ensure a perfect match for your project. The PS-900 is also compatible with other OK International products such as fume extraction systems and fluid dispensers.

Having explored the effects of heat, let’s move on to explore cooling techniques on the next page.

3. Kalamazoo FC350D Cold Saw

A cold saw is a specialized type of circular saw equipped with a coolant system that runs during the cutting process. This system helps reduce sparks, dust, and grit while keeping the saw cool, ensuring smoother cuts and extending blade life. Cold saws often feature powerful, rigid vises that securely hold materials in place without vibration, which plays a key role in producing precise cuts and preserving blade longevity.

Cold saws excel at cutting narrow tubes and small bars, and they’re also great for making accurate miter cuts, like the 45-degree angles often needed in doorframes. They are fitted with high-speed steel (HSS) blades, which are less resistant to heat and capable of cutting at faster speeds.

Let’s take a detailed look at one of Kalamazoo Machine Tool’s offerings: the FHC350D cold saw. This manual machine, made from cast iron, delivers burr-free cuts with ease. It’s equipped with circular HSS blades up to 14 inches (35 cm) in diameter, which can rotate at speeds of either 26 or 52 revolutions per minute, a setting you can adjust based on the material you're cutting.

After cutting all the materials into pieces, let's explore a fantastic tool on the next page that can help us reassemble everything. Unlike the small soldering system we read about earlier, perfect for detailed work, this hot air machine is designed for heavy-duty tasks.

2. Millermatic 252 MIG Welder

MIG welding, which stands for Metal Inert Gas, involves feeding a wire through the welding gun’s contact tip. A protective gas shield, also delivered through the tip, surrounds the welding area, safeguarding the electrode wire and keeping contaminants away to ensure a cleaner weld. The wire is energized with electricity, causing it to melt and create the weld puddle.

MIG welding, also known as GMAW (Gas Metal Arc Welding), sometimes uses semi-inert gases like carbon dioxide, though the term 'MIG' is still widely used. MIG welding has several advantages, including time savings, minimal clean-up, less waste, and, most importantly, the production of high-quality welds.

The Millermatic 252 MIG Welder is a prime example of MIG welding technology, priced at around $2,500 [source: Miller]. Equipped with wheels for easy mobility, this machine is perfect for light manufacturing, metal fabrication, and a variety of other workshop tasks.

The Millermatic can weld materials like steel, stainless steel, and aluminum, with a wire speed ranging from 50 to 700 inches per minute (roughly 1.3 to 17.8 meters per minute). You can preset various aspects of the welding process, offering greater control over each step. For example, the duration of the shield gas flow before the weld arc ignites can be customized. It also features memory functions to store settings for different types of welding guns that can be attached.

With all the heavy equipment and materials we've gathered, space is becoming a premium. Discover an innovative tool on the next page that makes moving all this gear around the workshop a breeze.

1. Sidewinder ATX-3000

Maneuvering forklifts and other vehicles can be tricky, mainly because their wheels only roll forwards and backwards, without any side-to-side motion. So, if you want to move to a spot on your right or left, like a better parking space, and stay aligned in the same direction when you get there, you'll need to go forward or backward, then turn again. While this is not such a big deal for cars, it's a different story for forklifts.

Forklifts are often used to transport large, bulky, and heavy items, which can be tough to load and even harder to maneuver, especially through tight spaces like doorways. The constant turning and slow speeds also consume a lot of time. This is where the last tool comes in handy – its wheels are designed to allow it to move in any direction, saving time and effort.

The groundbreaking wheel design was invented by Bengt Ilon from Sweden in the 1970s. The design uses a set of rollers arranged at angles along the wheel, creating a shape similar to a sphere (like the ball bearings in rolling chairs). This drastically increases the mobility of the vehicle, allowing it to move sideways, diagonally, or any other direction with ease.

These innovative wheels have found their way onto several commercial vehicles, including the Airtrax Sidewinder ATX-3000 forklift. This forklift is controlled by two joysticks and can rotate 360 degrees while remaining stationary. It can also drive over obstacles as high as 3 inches. One of its biggest advantages is that it takes up less space in a warehouse because the vehicle's movements are more efficient, allowing for faster maneuvers and more storage capacity.