Practical Enclosure Design, Optimized for 3D Printing

[3D Hubs] have shared a handy guide on designing practical and 3D printing-friendly enclosures. The guide walks through the design of a two shell, two button remote control enclosure. It allows for a PCB mounted inside, exposes a USB port, and is optimized for 3D printing without painting itself into a corner in the process. [3D Hubs] uses Fusion 360 (free to hobbyists and startups) in their examples, but the design principles are easily implemented with any tool.

One of the tips is to design parts with wall thicknesses that are a multiple of the printer’s nozzle diameter. For example, a 2.4 mm wall thickness may sound a bit arbitrary at first, but it divides easily by the typical FDM nozzle diameter of 0.4 mm which makes slicing results more consistent and reliable. Most of us have at some point encountered a model where the slicer can’t quite decide how to handle a thin feature, delivering either a void between perimeters or an awkward attempt at infill, and this practice helps reduce that. Another tip is to minimize the number of sharp edges in the design, because rounded corners print more efficiently and with smoother motions from the print head.

The road to enclosures has many paths, including enclosures made from FR4 (aka PCB material) all the way down to scrap wood with toner transfer labeling, and certainly desktop 3D printing has been a boon to anyone who’s had to joylessly drill and saw away at a featureless plastic box.

Blooming Flower Lamp Will Test Your 3D Printer

[ossum] has a baby on the way. He admits that he got a bit carried away, brimming with parental excitement. What resulted is a fully articulated LED WiFi lamp that blooms and glows dramatically in the friendly confines of the oncoming baby’s room.

We’ve covered [ossum]’s work before. As usual, he started off by showing his complete mastery of Fusion360 and making the rest of us look bad. If you want to learn 360, we recommend scrobbing through his models to see how it’s done.  The base encloses an ESP8266 and a hobby servo. A clever mechanism pulls down on a stranded steel cable that runs through the stem along with some control lines for the LEDS. This opens and closes the petals. The LEDs are all held in a 3D printed frame which produces a nice even glow.

If you’d like to build one yourself, there’s a full video viewable after the break. Files are available on Thingiverse. Just make sure you tune up your printer first, this is a tough one.

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Modular Drum Machine Creates Random Rhythms

Don’t worry, the rhythms themselves aren’t random! That would hardly make for a useful drum machine. [kbob]’s creation does have the ability to randomly generate functional rhythms, though, and it’s all done on a breadboard.

The core of this tiny drum machine is two Teensy dev boards. One is an FM synth tuned to sound like drums, and the other is a random rhythm generator with several controls. The algorithms are from Mutable Instruments’ open source Eurorack modules. The entire thing fits on a breadboard with JIGMOD modules for the user interface. The machine runs on lithium batteries in the form of USB cell phone chargers. The battery holders were designed in Fusion 360 and 3D printed.

The function of the drum machine is pretty interesting as well. There are a set of triggers tied to the buttons on the machine. When a button is pressed, the drum machine plays that sound at the appropriate time, ensuring there are no offbeat beats. The potentiometers are polled once every millisecond and the program updates the output as required. There’s also a “grid” of rhythms that are controlled with two other knobs (one to map the X coordinate and the other for the Y) and a “chaos” button which adds an element of randomness to this mapping.

The modular nature of this project would make this a great instrument to add to one’s musical repertoire.It’s easily customizable, and could fit in with any of a number of other synthesizer instruments.

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R/C Hot Rod Built Completely From Scratch

[ossum]’s R/C hot rod shows what’s possible when a talented hacker takes full advantage of all the modern resources available to them. The results are stunning.

[ossum] had a stack of Amazon and Shapeways credits lying around after winning a few competitions. He had this dream of building an R/C car for a while, and decided now was the time. After ordering all the needed parts from Amazon, he made an extremely nice model of the car in Fusion 360. The CAD model is a great learning resource. If you want to learn how to use reference photos, parts, and more to build a detailed and useful CAD model we recommend downloading it as a Fusion archive and scrubbing through the timeline to see how he did it.

Some of the parts were sent off for laser cutting. Others were 3D printed. The rest he made himself. Thanks to his model, they all went together well. You can see his R/C rod racing in the video after the break.

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