Maybe You Can Print in Metal

Let’s face it. Printing in plastic is old hat. It is fun. It is useful. But it isn’t really all that exotic anymore. The real dream is to print using metal. There are printers that handle metal in different ways, but they aren’t usually practical for the conventional hacker. Even a “cheap” metal printer costs over $100,000. But there are ways you can almost get there with a pretty garden-variety printer.

There’s no shortage of people mixing things into PLA filament. If you have a metal hot end and don’t mind wearing out nozzles, you can get PLA filament with various percentages of metal powder in it. You can get filament that is 50% to 85% metal and produce things that almost seem like they are made from metals.

[Beau Jackson] recently had a chance to experiment with a metal-bearing filament that has a unique twist. Virtual Foundry’s Filamet has about 10% PLA. The remaining material is copper. Not only do you have to print the material hot, but you have to print it slow (it is much denser than standard PLA). If it were just nearly 90% metal, that would be impressive, but nothing too exciting.  The real interesting part is what you can do after the print is complete. (If you don’t want to read, you can always skip to the videos, below.)

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This DIY Wearable Assist Goes Beyond Traditional Therapy

Bodo Hoenen and his family had an incredible scare. His daughter, Lorelei, suddenly became ill and quickly went from a happy and healthy girl to one fighting just to breathe and unable to move her own body. The culprit was elevated brain and spinal pressure due to a condition called AFM. This is a rare polio-like condition which is very serious, often fatal. Fortunately, Lorelei is doing much better. But this health crisis resulted in nearly complete paralysis of her left upper arm.

Taking an active role in the health of your child is instinctual with parents. Bodo’s family worked with health professionals to develop therapies to help rehabilitate Lorelei’s arm. But researching the problem showed that success in this area is very rare. So like any good hacker he set out to see if they could go beyond the traditional to build something to increase Lorelei’s odds.

What resulted is a wearable prosthesis which assists elbow movement by detecting the weak signals from her bicep and tricep to control an actuator which moves her arm. Help came in from all over the world during the prototyping process and the project, which was the topic of Bodo Hoenen’s talk at the Hackaday SuperConference, is still ongoing. Check that out below and the join us after the break for more details.

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Hackaday Links: November 13, 2016

The Travelling Hackerbox is going International. I wrote a post on this earlier in the week, and I’m still looking for recipients for the box that are not in the United States. The sign-up form is right here, [the sign up form is now closed] and so far we have good coverage in Canada, Australia, NZ, Northern Europe, and a few in Africa. If you ever want to be part of the Travelling Hackerbox, this is your chance. I’m going to close the sign-up sheet next week. Sign up now.

Like the idea of a travelling hackerbox, but are too impatient? Adafruit now has a box subscription service. Every quarter, an AdaBox will arrive on your doorstep packed to the gills with electronic goodies.

The very recently released NES Classic edition is the 2016 version of the C64 DTV — it’s a Linux system, not as elegant, and there’s little hacking potential. If you want to increase the amount of storage, desolder the Flash chip (part no. S34ML04G200TFI000), and replace it with a larger chip. The NES Classic edition isn’t the coolest retro system coming out — Genesis is back, baby. Brazil has had a love affair with the Genesis/Mega Drive because of their bizarre import restrictions. Now, the manufacturer of the Brazilian Sega clones is releasing a Linux-ified clone. Does anyone know how to export electronics from Brazil?

The CFP deadline for the SoCal Linux Expo is fast approaching. You have until the 15th to get your talks in for SCALE.

Let’s talk about dissolvable 3D printer support material. One of the first materials able to be printed and removed by dissolving in water was PVA. Makerbot sold it for use in their dual extruder machines. PVA does dissolve, but it degrades at higher temperatures and kills nozzles. HIPS can be dissolved with limonene, but it’s really only for use in conjunction with ABS. This week, E3D released their Scaffold support material. It’s a PVA/Polyvinyl alcohol filament — ‘the stuff gel caps are made out of’ was the line we got when E3D previewed Scaffold at MRRF last March. It’s a support material that’s water dissolvable, compatible with most filaments, and is able to produce some amazing prints. It’s available now, but it is a bit pricey at £45 for half a kilo. Brexit is a good thing if you’re paid in dollars.

If you’re into chiptunes, you’ve heard about Little Sound DJ. LSDJ is a cart/ROM capable of toggling all the registers on the Game Boy sound chip, sequencing bleeps and bloops, and generally being awesome. The recently released Nanoloop Mono is not Game Boy software. It’s a few op-amps and a PIC micro pasted on a board that turns the Game Boy into a synth. You get a significantly more 80s sound with the Nanoloop Mono over LSDJ, audio input, and a step sequencer.

3D Printing Permanent Magnets

Researchers at TU Wien wanted to create magnets with exactly the right magnetic field for a particular application. Their solution? 3D printing of magnets. Previously, it has been difficult to produce permanent magnets with a specific shape of the magnetic field. The resulting magnets will be a boon to magnetic sensor construction.

Previously, after designing a magnet with a specific shape and magnetic field, a researcher would have to create tooling for injection molding. This is expensive and time-consuming and often not worth it for small quantities of magnets.

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NASA Puts its 3D Models Up on GitHub

NASA has a bunch of its 3D models up on GitHub, and if you didn’t know about it before, you do now. It’s a ridiculously large download, at over one and a half jiggabytes, but it’s full of textures and high-resolution models of spacecraft, landing sites, and other random NASA ephemera.

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Variable Thickness Slicing For 3D Printers

With proper tuning, any 3D printer can create exceptionally detailed physical replicas of digital files. The time it takes for a printer to print an object at very high detail is another matter entirely. The lower the layer height, the more layers must be printed, and the longer a print takes to print.

Thanks to [Steve Kranz] at Autodesk’s Integrated Additive Manufacturing Team, there’s now a solution to the problem of very long, very high-quality prints. It’s called VariSlice, and it slices 3D in a way that’s only high quality where it needs to be.

The basic idea behind VariSlice is to print vertical walls at a maximum layer height, while very shallow angles – the top of a sphere, for example – are printed at a very low layer height. That’s simple and obvious; you will never need to print a vertical wall at ten micron resolution, and fine details will always look terrible with a high layer height.

The trick, as in everything with 3D printing, is the implementation. In the Instructable for VariSlice, it appears that the algorithm considers the entire layer of an object at a time, taking the maximum slope over the entire perimeter and refining the layer height if it’s necessary. There’s no weird stair stepping, overlapping layers of different thicknesses, or interleaving here. It’s doing automatically what you’d normally have to do manually.

Nevertheless, the VariSlice algorithm is now one of Autodesk’s open source efforts, just like the Ember resin printer used in the example below. The application for this algorithm in filament-based printers is obvious, though. The speed increase for the same level of quality is variable, but the time it takes to print some very specific objects can be up to ten times faster. Whether or not this algorithm can be integrated into Cura or Slic3r is another matter entirely, but we can only hope so.

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3D Print An Enigma Machine That’s Close To The Real Thing

The Enigma machine as used by the German military during World War Two exerts a curious fascination among our community of hardware hackers and makers. Perhaps it is the mechanical complexity of the machine itself, or maybe the tale of how its encoded messages were decrypted by Allied codebreakers that contributes to this interest, but whatever it is we’ve seen a succession of Enigma-related projects over the years that shows no sign of abating.

The latest Enigma project to come our way is a particularly nice one from a group of first year students at CentraleSupélec Rennes, in Northwestern France. Their Réplique Enigma is a fully mechanical Enigma replica using 3D printing techniques, and unlike so many replicas which use modern electronics it has a set of rotors just like those you would have found in the original. The rotors themselves have a 3D-printed plastic shell which houses brass contacts and the associated writing, while the keyboard and lamp board are both made from plywood. Rather than trying to replicate the original switches from the keyboard they are using modern microswitches, however the keys themselves are upright posts that resemble the original. An AZERTY layout may not have been present on the real Enigma machines, but lends a pleasing twist to the build.

It’s worth browsing all the pages for this build, as the front page does not necessarily capture the whole build. The rotors set this Enigma apart from many of the replicas we’ve featured in the past, so you may find it interesting to take a look and make a few comparisons.