LINKAGES: CRANK TOY ACTION
MECHANISMS AT WORK (& PL AY )
Cam toys convert rotational motion into linear motion. This simple machine is
a great project that provides an entrance to mechanical engineering, and can
integrate with a laser cutter and 3D printer to go from simple to spectacular.
The D.I.Wire makes it possible to create a working crank and cam system all in
one piece, so you can spend more time on the creative process. This makes
crank toys ideal intermediate-level projects that put imagination in motion.
SKILLS
Intermediate bending PROTOTYPING
Fabrication
Designing ENGINEERING
MATERIALS PROJECT OVERVIEW
Paper & drawing tools SETUP: 15 min.
Needle nose pliers
IDEATION: ~15 min.
Wire cutters
BENDING: 1 min. per crank shaft
Scissors & Tape
Materials shot 1/4” thick acrylic sheet HOUSING & PARTS: ~25 min. per toy*
(3”x3” squares, 2 per box) FULL ASSEMBLY: ~10 min.
Clear plastic foldable box, 3”x3”x3” TOTAL BUILD TIME: ~ 1.25 hour
(order online, or build your own)
Grommets can be purchased on the web: 1/8” diameter wire, ~14” per crank
This project can be broken into 2 or 3 shorter
sessions.
www.mcmaster.com/#9600k17/=13hroew 1/16” diameter wire, ~24” per toy
Rubber grommets *Add time if you don’t have a laser cutter.
PROJECT FILES:
Crank_toy_wire, Crank_toy_boxParts Lighter (optional) PensaLabs.com
DIWire@PensaLabs.com
SETUP, DESIGNING AND PLANNING
Gather your materials. It’s a good idea to plan ahead for storing in-progress projects
if you don’t have time to work all the way through in one sitting.
This project assumes you have gone through the basics of using the DIWire.
Pre-cutting wire down to a managable length is ok, just remember that this will
become a design constraint-- you’ll need about 6” more wire than the total of your
design’s vector length to allow the feed wheels enough to hold onto.
1.
Sketch out ideas for the moving parts: get creative!
DIGITAL FABRICATION:
LASER CUTTING & BENDING
2.
Download the file for the squares that hold
the crank. Cut one of each side piece per
crank toy. The acrylic should be at least 3.
1/4” thick to provide stability for the box 4.
and the crank action. You can cut thinner Slip the grommets onto the crank.
Download the crank file and open it in
material and stack it to a suitable thickness, Wiggle them until they are in the correct
Wireware. Bend out the crank, being
too. places for the pushers.
careful to keep the angles lined up for
smooth crank action. If you don’t have grommets, you can use
PensaLabs.com Make sure not to cut the crank too skinny rubber bands on either side of the
DIWire@PensaLabs.com short! pusher wires to hold them in position.
THE HOUSING
Assemble the plastic box by creasing and folding it, using a little tape to secure
it temporarily if necessary. There are many alternative options for building the
box that will hold the toy together. You can make your own box out of any
sturdy material, from thick cardboard to wood. Using a pre-made box is rec-
ommended to save time and make fabrication easier. The box needs to be able
to open on the top and sides for assembly, though.
5.
Search for these boxes online at Amazon: BOX REQUIREMENTS:
“Clear Plastic PVC Party Favor Boxes” sold Box dimensions for this project: 3”H x 3”W x 3”D (outer measurements)
by Durapak or other sellers.
Remember that thicker walls will affect what will fit inside, you may need to
You can also create free custom box files for adjust your crank accordingly. You can do that in Wireware or your vector art
the laser at www.makercase.com, software.
just make sure you adjust your crank files to
fit, and add the holes for the cranks to your Box must be sturdy enough to keep the crank in place during turning.
new box files.
MARKING FOR HOLES
6.
Make marks in the center of both
sides of the box where the ends of
the crank will go. Mark the top, too.
If you don’t have a transparent box
(or a lasercutter), you can draw lines
connecting opposite corners to find
the center of the sides.
PensaLabs.com
DIWire@PensaLabs.com
PUSHERS AND HOLES
PensaLabs.com
DIWire@PensaLabs.com
We like using the clear plastic box because it’s easy to make the holes and get the mechanism in. If you
made your own box, you will need to make sure your holes are all in the correct places and assemble it around the mechanism.
If you don’t want to use open flame in your space, you can use a screw or punch to poke the holes in the plastic box.
7. 8. 9.
Use the needlenose pliers to bend rounded hooks Use a lighter to heat the end of a pusher. It Poke through the top and inner flaps of the
that will loop onto the crank. Make them big does not need to be red hot, just hot enough box with the heated pusher wire where you
enough to go all the way around the grommets. to melt through 2 layers of plastic. marked with the marker. Also poke the holes
in the sides for the crank.
10. 11. 12.
Attach the pushers onto the crank. Be careful Stick the pushers up through the holes Flex the box a bit and fit the handle through the hole
not to pinch the pushers onto the grommets too in the top of the box. Put the stationary in the other side of the box so it sticks out.
tightly, or they will not allow the crank to turn end of the crank into the acrylic side Then slide the slotted acrylic side up under the
smoothly. Use the pliers to adjust the tightness. with one hole and slide it into place. handle.
FINISHING ASSEMBLY
After getting the acrylic sides into place,
close up the bottom of the box. You can
glue the acrylic to the sides of the box
(super glue works well) for a more rigid
structure.
Clip off the pushers to the length that you
want for your design.
13. 14. TIP: Rub ends of wire against sandpaper
taped to the table to take off sharp points
made by the cutters!
ATTACHING THE DESIGN
The design you choose will determine how you attach the moving parts to the pushers. Other ways to attach pieces to the pushers
include poking the pushers into slices of cork (attach anything to the cork) or winding thin, flexible wire or pipe-cleaners onto the
pushers. You can drill into small wood pieces, or even 3D print custom shapes, too.
15. 17.
Cut out the design. Attach the tape to the wire
and the paper.
This is a great place to get
creative. Allow for flopping When all the pieces are
or springy action, think attached, give it a few test
about using the whole turns. Make sure all the
length of the pusher, or 16. pieces are well-attached. 18.
creating a scene in motion.
PensaLabs.com
DIWire@PensaLabs.com
CRANKING IT UP A LEVEL:
MORE ADVANCED CRANK TOYS
Making more complex mechanisms is no
problem with digital fabrication.
Crank toys are part of the tradi-
tional art of automata, as well as a TIPS:
great introduction to mechanical
engineering. Rotate the wire during bends for a 2.5D twist
Add 3D printed elements
Connect the pieces with joints, linkages, or springs
for complex motion
Connect the crank to a motor
Rolling crank toy by Alexander Calder
(the axle acts as the crank) PensaLabs.com
DIWire@PensaLabs.com
