Awww Shoot! My Spool Doesn’t Fit My Holder


The great thing about standards is that there are so many to choose from. Filament spools certainly do not deviate far from this sarcastic saying. So what are we 3D Printer folks to do? Here are a couple completely different DIY options:

[Mark] made a spool holder that can accept 2 different width spools. This design uses skate bearings to support the spool on two points at each end. There are 3 sets of bearing blocks to accommodate the 2 different width spools. When either size spool is installed, one of the bearing block sets goes unused.

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A 3D Printed Cryptex


Once you’ve dialed in your 3D printer calibration settings, you enter the phase of printer ownership where you’re eager to show off what you can make, and you’re sure to impress with [pjensen's] 3d printed cryptex spinning around in your hands.

If you’re a regular reader of our 3D Printering column, then the behind-the-scenes screengrabs should look familiar: [pjensen] used Autodesk Inventor to sculpt the shapes, staring with the cryptex’s individual rings. After embossing the alphabet across each ring, [pjensen] adds slots into the inner loops for pins to slide through. An outer chamber holds the rings in place and prohibits access to the interior chamber, which is held in place on both sides by an end cap.

Lining up the rings to spell the correct word allows the inner chamber to slide free of the whole assembly, revealing whatever goodies may lie inside. You can follow [pjensen's] step-by-step guide to build your own cryptex, or just download his model and start printing.

Resetting DRM On 3D Printer Filament


The Da Vinci 3D printer is, without a doubt, the future of printing plastic objects at home. It’s small, looks good on a desk, is fairly cheap, and most importantly for printer manufacturers, uses chipped filament cartridges that can’t be refilled.

[Oliver] over at Voltivo was trying to test their new printer filament with a Da Vinci and ran head-on into this problem of chipped filament. Digging around inside the filament cartridge, he found a measly 300 grams of filament and a small PCB with a Microchip 11LC010 EEPROM. This one kilobyte EEPROM contains all the data about what’s in the filament cartridge, including the length of filament remaining.

After dumping the EEPROM with an Arduino and looking at the hex file, [Oliver] discovered the amount of filament remaining was held in a single two-byte value. Resetting this value to 0xFFFF restores the filament counter to its virgin state, allowing him to refill the filament. A good thing, too; the cartridge filament is about twice as expensive as what we would normally buy.


Building a Quadcopter with a CNC Mill and a 3D Printer


Quadcopters are a ton of fun to play with, and even more fun to build. [Vegard] wrote in to tell us about his amazing custom DIY quadcopter frame that uses a commercial flight control system.

Building a quadcopter is the perfect project to embark upon if you want to test out your new CNC mill and 3D printer. The mechanical systems are fairly simple, yet result in something unbelievably rewarding. With a total build time of 30 hours (including Sketchup modeling), the project is very manageable for weekend hackers. [Vegard's] post includes his build log as well as some hard learned lessons. There are also tons of pictures of the build. Be sure to read to read the end of the post, [Vegard] discusses why to “never trust a quadcopter” and other very useful information. See it in action after the break.

While the project was a great success, it sadly only had about 25 hours of flight-time before a fatal bird-strike resulted in quite a bit of damage. Have any of your quadcopters had a tragic run-in with another flying object? Let us know in the comments.

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Dispensing Solder Paste With A 3D Printer


There’s a strange middle ground in PCB production when it comes to making a few boards. Dispensing solder paste onto one board is easy enough with a syringe or toothpick, but when pasting up even a handful of boards, this method gets tiresome. Solder paste stencils speed up the process when you’re doing dozens or hundreds of boards, but making a stencil for just a few boards is a waste. The solution for this strange middle ground is, of course, to retrofit a 3D printer to dispense solder paste.

This project was a collaboration between [Jake] and [hzeller] to transform KiCAD files to G Code for dispensing solder paste directly onto a board. The machine they used was a Type A Machines printer with a solder paste dispenser in place of an extruder. The dispenser is hooked up to the fan output of the controller board, and from the looks of the video, they’re getting pretty good results for something that’s still very experimental.

All the code to turn KiCAD files into G Code are up on [hzeller]‘s github. If you’re wondering, the board they’re pasting up is a stepper driver board for the BeagleBone named Bumps.

Videos below.

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Ask Hackaday: Auto Bed Leveling And High Temperature Force Sensitive Resistors


[Johann] over on the RepRap wiki has an ingenious solution for making sure a borosilicate glass bed is completely level before printing anything on his Kossel printer: take three force sensitive resistors, put them under the build platform, and wire them in parallel, and connect them to a thermistor input on an electronics board. The calibration is simply a bit of code in the Marlin firmware that touches the nozzle to the bed until the thermistor input maxes out. When it does, the firmware knows the print head has zeroed out and can calculate the precise position and tilt of the bed.

Great, huh? A solution to bed leveling that doesn’t require a Z-probe, uses minimal (and cheap) hardware, and can be retrofitted into just about any existing printer. There’s a problem, though: these force sensitive resistors are only good to 70° C, making the whole setup unusable for anything with a heated bed. Your challenge: figure out a way to use this trick with a heated bed.

The force sensitive resistors used – here’s a link provided by [Johann] – have a maximum operating temperature of 70° C, while the bed temperature when printing with ABS is around 130° C. The FSRs are sensitive to temperature, as well, making this a very interesting problem.

Anyone with any ideas is welcome to comment here, on the RepRap forums, the IRC, or anywhere else. One idea includes putting an FSR in the x carriage, but we’re thinking some sort of specialized heat sink underneath the bed and on top of the FSRs would be a better solution.

Video of the auto bed leveling trick in action below.

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4 Axis Delta Router Says Hello World


[Bart] stood upon the shoulders of the delta 3D printer giants and created this 4 axis delta router. The router was originally created for ORD Camp, an invite only hackers gathering. Each year he creates a new thing with one main purpose: to spark conversation. In his own words “Practicality and suitability are way down the list, so go ahead and snark away. If you do, you are missing the point.”

[Bart] did things a bit differently with his delta. For motors, he went with non captive steppers. “Non captive” means that rather than a shaft, the motor has a hollow threaded nut which rotates. A lead screw (usually with an acme thread) is passed through this nut. As the motor’s nut turns, the screw is pushed or pulled through the motor, creating a linear actuator. The only major downside is that a non captive stepper motor can’t be adjusted by hand. The screw doesn’t turn and neither do any external parts of the motor. For structure, the router uses MakerSlide and v-grove wheels. The spindle is a simple brushless hobby motor and 30 amp speed control. Rather than the outrunner motors we’ve seen lately, [Bart] wisely chose an inrunner motor normally used on R/C cars. Inrunners generally have less torque than their outrunner counterparts, but they make up for this in RPM. [Bart's] motor is capable of 30,000 RPM, which is plenty for spindle duty. We think the motor bearings will probably need an upgrade, as the original motor bearings weren’t designed for side loads. For a controller, [Bart] utilized an  Azteeg X3 running Repetier.

The router made a great showing at camp, and [Bart] decided it needed a 4th axis. He sourced a rotary axis from eBay. To keep the software simple, he connected the rotary axis to the extruder outputs on his controller. He was then able to hack the mach3 wrapped rotary post processor to output extruder commands. The results look great. [Bart] says the system definitely needs a tailstock, and we agree. We’re looking forward to the next update on this machine!

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