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Yes, a hobbyist can build an automatic paper tape punch, but the precision punch-and-die assembly and the timing between punching and feeding are the hard parts. Simon Boak’s documented prototype shows one workable approach: machine a close-fitting die, use hardened-steel punch rods, actuate them with leveraged 12 V solenoids, and control the sequence with an Arduino-based board. It targets one-inch tape with eight data holes and a smaller sprocket hole; its dimensions are project-specific, not universal.
What the documented machine does
Simon Boak’s June 2025 project converts serial input into holes in paper tape and includes an optional path for parallel data. The build account and public design files are available from the project’s GitHub repository; Hackaday’s June 23, 2025 overview summarizes the design. The repository lists Arduino source, PDF schematics, CAD and KiCad files, under an MIT license.
The maker says the prototype follows the one-inch, eight-data-hole format associated with ISO 1154. In this particular build, data holes are 1.8 mm and the sprocket hole is 1.3 mm. Confirm the required format, hole geometry and code against the reader or machine that will use the tape before making a die: historical systems do not all share the same configuration. A Hackaday commenter also points to ECMA-10 as a standards lead, but the project’s stated dimensions should not be treated as a substitute for checking the target system.
How the punch-and-die assembly is made
Machine the die before assembling the actuators
The die is the most demanding fabrication step. The holes must align with the punches and with the tape path; closely spaced openings make accurate layout and machining important. Boak made two matching die pieces and screwed them together with a slot between them for the tape. The build account does not provide validated manufacturing tolerances or endurance results, so it cannot supply a universal clearance specification.
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Shape and mount the punches
Boak used round HSS shanks from drill bits as punch stock, reporting 1.8 mm rods for the data holes and a 1.3 mm rod for the sprocket hole. The tips were ground into a concave cutting profile and fixed into 3D-printed carriers. Those are the documented project’s choices; they are not guaranteed dimensions or materials for other tape formats. Punch tips and openings must match closely enough to cut cleanly without binding.
Use leverage to reduce the direct actuator burden
The prototype uses 12 V solenoids with mechanical leverage, rather than asking each solenoid to provide the full punch force directly. Boak reports about 1.7 A per solenoid and configures the machine to fire one at a time. That project-specific current draw is an important power and throughput trade-off, not a general specification for solenoids. The custom controller is Arduino Nano-style; the optional parallel-input components were not yet soldered onto the board when the project account was published.
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Why feed timing and hole quality need careful tuning
The tape must not advance while a punch is still engaged. Boak reports occasional tearing when a punch failed to retract completely before feed movement, as well as hanging chads on some punches. These defects point to punch sharpness, die clearance, return action and feed interlocking as areas to inspect. They also mean the build should be treated as a prototype, not as a finished or production-tested machine.
A practical way to develop the mechanism is to begin with individual punches and inspect the results before relying on a full sequence. Check that each pin clears the tape before the feed advances, then look for incomplete cuts, chads, binding and tearing. This is an engineering response to the failure modes Boak reports, not a published test protocol or a claim of a proven operating speed.
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Choosing a mechanical architecture
A 2020 practitioner discussion describes two broad historical approaches: actuating punches directly with solenoids, including linear or rotary arrangements, or using a motor-driven crank or cam to supply the force while small solenoids move spring-metal interposers to select pins. A knee-joint variation is also mentioned. The discussion is an engineering overview, not a manufacturer service manual or exhaustive taxonomy.
| Design choice | Potential advantage | Trade-off to evaluate |
|---|---|---|
| Direct solenoid actuation with leverage, as in Boak’s prototype | A comparatively straightforward mechanism with fewer moving parts | Requires sufficiently strong actuators; current demand can constrain simultaneous punching and throughput |
| Motor-driven crank or cam with selecting interposers | The motor supplies the punching force while smaller solenoids select which punches engage | More mechanical components and timing relationships to design and maintain |
The available accounts do not give controlled measurements comparing speed, force, reliability, accuracy, maintenance or cost. Choose an architecture by considering the die and punch precision you can make, the actuator and power supply, whether punches must fire together, the number of moving parts, the tape and feed requirements, and compatibility with the destination machine.
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Getting tape stock
Blank tape was another challenge in Boak’s build. The maker used 57 mm thermal-paper rolls and a 3D-printed slitter with installed blades to cut narrower stock. The account reports that this light material needs relatively little punching force. This is one builder’s workaround, not an independent evaluation of thermal-paper coatings or a guarantee that a particular roll is suitable for every reader or mechanism.
The project write-up also notes that traditional paper tape was oil-impregnated to lubricate mechanisms, a consideration more relevant to high-speed machinery than this prototype. Tape material, width and lubrication should therefore be considered alongside the reader and the intended feed speed rather than assumed from the prototype.
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Alternatives if a mechanical punch is not essential
A computer-controlled craft cutter or a laser-based patterning approach may avoid building a solenoid punch mechanism. The 2020 discussion mentions Cricut- or Silhouette-style cutters and the PTAP2DXF workflow; Boak’s project account also notes laser cutting as an option. The cited sources do not establish comparative accuracy, speed, cost or material suitability, so investigate these as possible approaches rather than drop-in replacements.
Before you build
- Identify the receiving reader or machine, its tape width, hole geometry and code before designing the die.
- Decide whether your expected throughput requires simultaneous punches or can tolerate sequential actuation.
- Plan the punch-and-die alignment, pin return and feed interlock as one mechanism.
- Choose tape stock with the feed path and intended operating conditions in mind; do not assume all thermal paper or lubrication practices are interchangeable.
- Allow time to tune the cutting profile and clearance: the documented prototype experienced chads and occasional tearing.
System-specific perforators also existed as part of larger equipment. For example, the 1971 Burroughs assembler manual documents a Style A 562 paper-tape/edge-punched-card perforator as an output adjunct. It is a reminder to check the actual system requirements rather than assume that one DIY machine’s geometry fits every historical setup.
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