MRRF 17: E3D Introduces Combination Extruder And Hotend

Since the beginning of time, or 2006, the ‘hot glue gun’ part of our CNC hot glue guns have had well-defined parts. The extruder is the bit that pushes plastic through a tube, and the hot end is where all the melty bits are. These are separate devices, even though a shorter path from the extruder to hotend is always better. From Wade’s gear extruder to a nozzle made from an acorn nut, having the hotend and extruder as separate devices has become the standard.

This week at the Midwest RepRap Festival, E3D unveiled the Titan Aero. It’s an extruder and hotend rolled into one that provides better control over the filament, gives every printer more build height, and reduces the mass of a 3D printer toolhead.

 

The aluminum thermal block of the Titan Aero

The Titan Aero, revealed on the E3D blog yesterday, is the next iteration of E3D’s entry into the extruder market. It’s a strange mashup of their very popular V6 hotend, with the heat break coupled tightly to the extruder body. A large fan provides the cooling, and E3D’s thermal simulations show this setup will work well.

The core component of the Aero extruder is a fancy and complex piece of milled aluminum. This is the heatsink for the extruder and provides the shortest path possible between the hobbed gear and the nozzle. This gives the Aero better control over the extrusion of molten plastic and makes this the perfect extruder and hotend setup for hard to print materials.

Combine the Aero with a smaller ‘pancake’ stepper motor, and you have a very small, very light hotend and extruder. This makes it perfect for the small printers we’re so fond of and for printers built for fast acceleration. I can easily see a few end effectors for Delta-style printers built around this extruder in the near future.

E3D’s Volcano nozzle sock

Also at the E3D booth were a few prototypes of nozzle socks. Late last year, E3D released silicone nozzle covers – we’re calling them nozzle socks – for their V6 hotend. These are small silicone covers designed to keep that carbonized crap off of your fancy, shiny hotend. It’s not something that’s necessary for a good print, but it does keep filament from sticking to your hotend, and you get the beautiful semantic satiation of saying the words nozzle socks.

E3D’s other hotend, the Volcano, a massive and powerful hotend designed to push a lot of plastic out fast, did not get its own nozzle sock at the time. Now, the prototypes are out, and the E3D guys expect them to be released, ‘in about a month’.

MRRF 17: Lulzbot and IC3D Release Line Of Open Source Filament

Today at the Midwest RepRap Festival, Lulzbot and IC3D announced the creation of an Open Source filament.

While the RepRap project is the best example we have for what can be done with Open Source hardware, the stuff that makes 3D printers work – filament, motors, and to some extent the electronics – are tied up in trade secrets and proprietary processes. As you would expect from most industrial processes, there is an art and a science to making filament and now these secrets will be revealed.

IC3D Printers is a manufacturer of filament based in Ohio. This weekend at MRRF, [Michael Cao], founder and CEO of IC3D Printers announced they would be releasing all the information, data, suppliers, and techniques that go into producing their rolls of filament.

According to [Michael Cao], there won’t be much change for anyone who is already using IC3D filament – the materials and techniques used to produce this filament will remain the same. In the coming months, all of this data will be published and IC3D is working on an Open Source Hardware Certification for their filament.

This partnership between IC3D and Lulzbot is due in no small part to Lulzbot’s dedication to Open Source Hardware. This dedication is almost excessive, but until now there has been no option for Open Source filament. Now it exists, and the value of Open Source hardware is again apparent.

MRRF 17: The Infinite Build Volume Printer

Before we dig into this one, a bit of a history lesson is in order. In 2010, MakerBot released the Automated Build Platform for the MakerBot Cupcake. This build platform was like nothing seen before or since. It’s a combination build platform and a conveyor belt for a 3D printer, allowing the Cupcake to become a completely automated production machine. Start a print, let the machine run, and when the print is finished it’s rolled off the bed into a bin, allowing a second print to start. If you’re using 3D printers for production in a manufacturing context – like Makerbot was – this is a phenomenal invention.

The Automated Build Platform was released under an Open Source license, then quickly patented by Makerbot. Since 2010, the idea of an automated build platform has been dead. No one is working on a similar device, lest they draw the ire of a few MakerBot lawyers.

This year’s Midwest RepRap Festival saw a device that’s an even better idea than MakerBot’s Automated Build platform. Yes, it’s a continuous factory of 3D printed parts, but there’s an even better reason for you to build one of these things: this printer has an infinite build volume.

This printer – it doesn’t have a name; this is just a one-off project – is the work of [Bill Steele] of Polar3D. The core of the build is just a hacked up MakerBot Replicator, but with one important difference. This printer has an Automated Build Platform tilted away from the nozzle at a 45-degree angle. What’s the benefit of this setup? Continuous printing and an infinite build volume.

Despite being downright bizarre, the mechanics for this printer are actually pretty simple. The bed is a standard MakerBot heated bed, rotated 90 degrees in the axis you would expect, then rotated 45 degrees in the axis you wouldn’t. A conveyor belt made of Kapton-coated paper is strung between two rollers and connected to a motor.

To produce a print, this printer starts at the very back and the very top of this conveyor belt. The first layer is added, the conveyor belt rolls forward a bit, and the second layer is added on top. The effect for each print is that the layer lines are 45 degrees from what you would expect.

When the print is finished, the belt just rolls forward until the part falls into a bin. Of course, since there’s nothing stopping this printer from producing a meter-long part on this build platform. [Bill] has already produced a 3D printed chain using this printer that was four feet long. Each segment of the chain just fell off the end of the printer when it was done.

There’s still some work to do with this idea. There isn’t a way to tension the belt on this printer, and [Bill] is looking for a material that’s better than Kapton coated paper. Still, this is the most innovative printer you can find at the Midwest RepRap Festival, and it’s not encumbered by the MakerBot patent on the automated build platform. You can check out a video of this printer below.

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The Think Tank at the Chicago Unconference

On Saturday the Hackaday community turned out in force to try something new. The first Hackaday Unconference was held in three places at the same time, and I was in Chicago and was amazed at the turnout and variety of presentations. The image above sums up the concept quite well, everyone shows up ready to give an eight minute talk, but as a whole, no one knows what to expect. Well, we should have known to expect awesome and that’s what we got.

As usual, people are excellent… to one another and in adapting to the fluid nature of the day. Pumping Station: One, a renowned Hackerspace in the Avondale neighborhood near downtown Chicago, opened their doors for us. Not knowing how many people to expect we set up two presentation rooms with a third on deck just in case it was needed.

We just barely squeezed everyone in one room for the first track but ended up splitting into two for part of the day. Here you can see that second room filling up. Even so we still had a handful of presentations that didn’t get a chance to shine — we simply must do this again so they can have the chance and because I had such a great time!

Continue reading “The Think Tank at the Chicago Unconference”

Hackaday Unconference Begins!

This afternoon we are hosting the Hackaday Unconference in three locations at once. Hundreds of creative minds are coming together in Chicago, Los Angeles, and San Francisco for an amazing day of shared inspiration.

You can get a little taste of what is happening by following along with the pulse of the events. Each will be doing some Facebook Live streams so look for that and regular posts on Hackaday Facebook. We’ll be regularly Tweeting and posting to Instagram. It would be absolutely fantastic if you would like and share those messages. Check out the Hackaday TweetWall for a collection of all the #HackadayUncon updates.

The goal is to break down barriers for sharing great ideas which will become the inspiration for new projects to come. Today’s overarching theme is “Build Something That Matters. Everyone attending is ready to give an eight-minute talk about something that interests them, without the pressure of a strict talk order or expectations of polished decks and eloquent delivery. As the Unconference progresses, new discussion groups and impromptu talks take bloom as everyone in attendance guides the direction of the day.

Hardware Tribes Growing Up Around Artisanal Electronics

Consumer electronics are design beasts that must serve many masters. There’s a price point for the product itself, a ceiling for the feature set (lest it not be ‘user friendly’), and to take the risk of actually manufacturing something there needs to be proof of the market. A lot of great things make it through this process, but some really unique and special gear goes completely around it.

So is the story of this AND!XOR hardware badge being built for DEF CON 25. This is not the official conference badge, but the latest in a growing trend of hardware/firmware engineers and hackers who design their own custom gear for the conference, trying to one-up not just the official badge, but the other hardware tribes doing the same. This unique hardware excitement is a big reason that Hackaday has developed electronic badges for our conferences.

The new badge is a mashup of Bender from Futurama and Raoul Duke from Fear and Loathing in Las Vegas, presents something of monstrosity to hang around your neck. That has certainly never stopped us from having one of these bouncing around our necks as we pound the cattle paths from talk to talk (and the DC23 vinyl record was way more unwieldy anyway).

Bender’s forehead display has now been upgraded from a diminutive OLED to a generous color LCD display. The 433 MHz which used the spring antenna on the previous badge has given way to a Bluetooth Low Energy. The BLE is built into the Rigado BMD-300 SOC that is now in conrol of the badge. We can’t wait to see the shenanigans unlocked with this new hardware — they’re already showing of crazy animations, retro gaming, and teasing a huge multiplayer game with all the badges. Finally, the “Secret Component” at the bottom of their components list delivers the je ne sais quoi to the whole project.

Fans of AND!XOR have already thrown their weight behind it. Unofficial badges have been unavailable to a wider group or only offered in flash-sales that pop up during the con. Last year the team was met with a huge mob throwing money at their supply of 175 badges. Now the AND!XOR team has grown to five people toiling away to make the design, the easter-egg laden firmware, and the manufacturing process better than the amazing work of last year. They just launched a crowd funding campaign on Tuesday and immediately blew past their goal about five times over.

We’re hoping to get our mitts on one of these ahead of DEF CON to give you an early look at what these hardware artists have accomplished. If you’re part of another hardware tribe building custom electronics for the love of it, we’d really like to hear from you. This goes for any conference — we know of at least one other in progress.

Hackaday Unconference this Saturday (in Triplicate)

This Saturday we’re hosting the Hackaday Unconference — three live events in Chicago, Los Angeles, and San Francisco that are going to jumpstart the idea engines and enthusiasm of everyone who attends. We can’t even tell you what the Unconference is about; it’s the people who participate that make the schedule and guide the discussion. Everyone there will be ready to give a talk of at least eight minutes on something that excites them right now. As the day goes on, ideas will feed off of each other and people will give talks and lead discussions they hadn’t even thought of before hearing other presentations of the day. It’s an atmosphere that you’ve never experienced unless you’ve been to an Unconference.

If you are located near one of these events it’s not too late to sign up. We’ve expanded the RSVP limit for Chicago and Los Angeles. And San Francisco has a waiting list that will likely be released at some point this week. So sign up now!!

Those not located nearby can still peek in to see what’s happening. We’ll be covering all three events on Hackaday Twitter,  Hackaday Facebook (including some Facebook Live blips throughout the day), and Hackaday Instagram using the #HackadayUncon hashtag. While you’re looking through all the ways to stay connected with us, you should sign up for the weekly Hackaday.com newsletter to pick up any stories you might have missed and get a few hints of what is ahead.