Koenigsegg 3D-Printing for Production Vehicles

Koenigsegg with Printed Parts

We’re not surprised to see a car manufacturer using 3D-printing technology, but we think this may be the first time we’ve heard of 3D-prints going into production vehicles. You’ve likely heard of Christian von Koenigsegg’s cars if you’re a fan of BBC’s Top Gear, where the hypercar screams its way into the leading lap times.

Now it seems the Swedish car manufacturer has integrated 3D printing and scanning into the design process. Christian himself explains the benefits of both for iterative design: they roughed out a chair, adjusting it as they went until it was about the right shape and was comfortable. They then used a laser scanner to bring it into a CAD file, which significantly accelerated the production process. He’s also got some examples of brake pedals printed from ABS—they normally machine them out of aluminum—to test the fits and the feeling. They make adjustments as necessary to the prints, sometimes carving them up by hand, then break out the laser scanner again to capture any modifications, bring it back to CAD, and reprint the model.

Interestingly, they’ve been printing some bits and pieces for production cars out of ABS for a few years. Considering the low volume they are working with, it makes sense. Videos and more info after the jump.

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Ask Hackaday: Can The Lix 3D Printing Pen Actually Work?

Lix

Introducing Lix, the world’s smallest 3D printing pen that allows you to draw plastic structures in 3D. It’s only been on Kickstarter for a few days now, and already it has garnered close to a million dollars in pledges. An astonishing achievement, especially considering we can prove – with math and physics – that it doesn’t work as advertised. However, we’re wondering if it could work at all, so we’re asking the Hackaday community.

The device is powered through a USB 3 port. In the video, the Lix team is using a MacBook Pro. This has a USB port capable of delivering 900 mA at 5 Volts, or 4.5 Watts. Another 3D printing pen, the 3Doodler, uses a 2A, 12V power adapter, equal to 24 Watts. Considering the 3Doodler works, and they both do the same basic thing, there’s something extremely odd going on here.

Just as a comparison, here’s a wirewound resistor commonly found in the heating element or ‘hot end’ of a 3D printer. It’s a 6.8  Ohm resistor powered at 12 Volts. That’s 21 Watts. Here’s a heater cartridge, also found in quite a few hot ends. It sucks down 40 Watts. Once again, the Lix Kickstarter clearly shows the pen extruding filament using only 4.5 Watts of power. Something is really, really fishy here.

Intuition doesn’t hold a candle to math, so let’s figure out exactly why it won’t work.

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Dual Color Extruder With A Single Stepper

extruder

Once you have a 3D printer able to build a few objects in a single color, the next logical upgrade is a dual extruder. A dual extruder allows for multiple color prints, and by adding a dissolvable filament, the ability to print object that would otherwise be impossible. Fitting a dual extruder on an existing 3D printer presents a problem: simply by using a second stepper motor, you reduce the print area of your printer significantly. That’s the problem Dglass 3D aims to solve with their extruder. It’s a dual filament extruder that uses only one stepper motor and takes up less space than some other single filament extruders.

This isn’t the first time the guys at Dglass 3D have tried Kickstarting a dual filament extruder; last year we saw a very similar mechanism that used a single stepper motor to feed two filaments. This older model lacked retraction, though, meaning two colored prints would range somewhere between messy, inaccurate, to impossible.

The new extruder uses a servo to ‘latch’ the filament and drive it into the hot end. This means retraction of the filament is possible and from the sample prints with this extruder, the results look pretty good.

Below You’ll see a few video demos of the dual color/retraction extruder printing an object in black and white filaments at the same time. It’s very cool, and with the addition of a dissolvable filament means very complex objects can be printed very easily.

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Hackaday Links: February 9, 2014

hackaday-links-chain

Here’s a quick tip to extend the usefulness of your multimeter. It’s a set of mini test hooks soldered to alligator clips with a short hunk of stranded wire in between. You can buy mini test hooks that go right on the metal probes of your meter, but the weight and bulk of the meter probes and cords sometimes get in the way. This rig allows more flexibility because of that wire.

Staying on the theme of test equipment tips, here’s a simple way to make a Y-connector for logic analyzers. [Thomas] uses a dual-row pin header, shorting each pair of pins so that both rows are connected. When this is plugged into a pin socket it leave two pins for connecting your test equipment and the rest of the project hardware.

After seeing our feature of a 3-wire Character LCD [Chad] wrote in to mention he built a 1-wire version using an ATmega328.

If you’re going to be in Anaheim this week you can stop by the ATX-West expo and see a 3D printer with a 1m x 1m x 0.5m printing area. [Thanks Martin]

Speaking of 3D printers, here’s a big delta robot (seven feet tall) outfitted for alternative material printing. It’s printing a CT scan of ribs and a heart in hot glue. This seems to be a popular material for more artistic uses. We just saw a hexapod which deposits hot glue as it roams.

The weaponized quadcopter post from Tuesday was a controversial one. The really bad part of it was the laser, which strapped to anything is extremely dangerous. But the other hack may have just been poorly executed. Hackaday alum [Jeremy Cook] wrote in to mention that fireworks and quadcopters can be used more responsibly. He strapped a sparkler to his quadro and used it to make light graffiti. You may remember that [Jeremy] wrote an introduction to light graffiti for us back in November.

faBrickation: Combining Lego and 3D Printing

faBrickation

While 3D printing gives you the ability to fabricate completely custom parts, it does have some drawbacks. One issue is the time and cost of printing large volumes. Often these structures are simple, and do not require completely custom design.

This is where the faBrickation system comes in. It allows you to combine 3D printed parts with off the shelf LEGO bricks. The CAD tool that lets you ‘Legofy’ a design. It creates directions on how to assemble the LEGO parts, and exports STL files for the parts to be 3D printed. These custom bricks snap into the LEGO structure.

In their demo, a head mounted display is built in 67 minutes. The same design would have taken over 14 hours to 3D print. As the design is changed, LEGO blocks are added and removed seamlessly.

Unfortunately, the tool doesn’t appear to be open source. It will appear for the ACM CHI Conference on Human Factors in Computing Systems, so hopefully we will see more in the future. Until then, you can watch the demo after the break.

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3D Printering: Making A Thing In Blender, Part I

printering

In case you weren’t aware, having a 3D printer is nothing like owning a real-life Star Trek replicator. For one, replicators are usually found on Federation starships and not hype trains. Secondly, the details of how replicated objects are designed in the 24th century is an issue completely left unexplored by TNG, and DS9, and only a minor plot point in a few Voyager episodes. Of the most likely possibilities, though, it appears replicated objects are either initially created by ‘scanning’ them with a teleporter, or commanding the ship’s computer to conjure something out of the hologrid.

No, with your own 3D printer, if you want a unique object you actually have to design it yourself. Without a holodeck. Using your hands to move a mouse and keyboard. Savages.

This series of ‘Making a Thing’ tutorials aims to fix that. With this post, we’re taking a look at Blender, an amazing 3D modeling and animation package.

Because we still haven’t figured out the best way to combine multiple blog posts together as a single resource − we’re working on that, though − here’s the links to the previous “Making a Thing” posts:

This list is sure to grow thanks to your suggestions on what 3D modeling software to feature, but for now let’s make a thing in Blender.

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Jello Shot Printer

IMG_5931
While inspecting some jello shots for a friend’s upcoming 25th birthday, [Sprite_tm] had an epiphany. What if you could print designs inside the jello shots? He quickly grabbed a syringe and proceeded to inject food dye into one of the jello shots — it worked. Unfortunately, his friend pointed out that it would take far too long to do each jello shot by hand, to which [Sprite] responded:

Never mind that, I’ll just whip up  a 3D printer that can make nice figures in the jelly for you.

Classic. The great thing about the hacker-mindset is that you never say no when confronted with a problem!

To achieve this printer, [Sprite_tm] has taken a handful of old CD-ROM drives to create a three axis moving platform. He’s using a forth drive’s ejector assembly to depress a syringe which pushes a concoction of banana liquor, green food colouring and cornstarch through medical tubing to the ink-head. To control it, he’s just using an ATTiny2313 with a mere 2K of memory. It took a bit of fiddling with to find the right flow, but works surprisingly well. Stick around after the break to see its printing capabilities.

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