Take That Mario! 3D Printed Red Tortoise Shell Armor!

Between all the media coverage of using 3D printers for human prosthetics, some individuals are making a difference for animals too by using 3D printing. And here’s one we really didn’t expect;  a replacement shell for a tortoise!

We’ve all seen the heartwarming articles about pups getting wheels, or dogs getting replacement sprung feet — but is there any love for [Cleopatra] the Tortoise? Canyon Critters Rescue is an animal rescue based out of Golden, Colorado. The founder [Novelli] had recently took in little [Cleopatra] who had a painful and dangerous bone disease where her shell peaks and gets worn out — and without a shell to protect her, could easily become infected. This is typically caused by poor nutrition, so the rescue fixed her diet, but the damage to her shell was already done.

At a public education program for the rescue, [Novelli] made an offhand comment about how cool it would be to 3D print a replacement shell for her to protect the weak spots. Lucky enough for [Cleopatra], someone from the Colorado Technical University was there and wanted to help.

First they 3D scanned [Cleopatra’s] shell, and then created a 3D model of it optimized for 3D printing. They printed miniature test models on a MakerBot, and once satisfied printed the entire thing in 4 pieces. It fits over top of original shell, protecting the weak areas.

It was an incredible learning experience for all involved, and [Novelli] was extremely grateful for the help he received from the community:

I am grateful to all these people volunteering their time and energy to help me. At the rescue I don’t have the resources or funds to do something of this scale.

As for [Cleopatra], she’s living a happy tortoise life once again — and since she’s only in her teens, she has nearly a century of life to look forward to with thanks to 3D printing.

3D Printed Desklamp Follows Tesla for Cordlessness

If not for [Nikola Tesla], we’d be pretty behind when it comes to electricity. So to pay homage to one of the greatest inventors, [David Choi] decided to make his very own wireless Tesla Desk Lamp!

As expected, [David’s] a big fan of [Nikola], and has always been inspired by his life and experiments — in particular he loves wireless power. Ever since he saw a Tesla Coil light up a bulb from a distance he was smitten. He even named his cat Tesla.

The funny thing is, [David] actually failed physics in high school, but a few years later decided to pursue it as a career while attending Wesleyan University. It didn’t stop when he graduated, he also studied electronic design in his spare time — which is where he learned about resonance.

Wanting to apply what he had learned he has created a very unique wireless desk lamp. Don’t let the pictures fool you; it’s actually 3D printed! It uses one of those retro “vintage” light bulbs, which has it’s power transmitted to it wirelessly by a 6.5MHz signal. It was relatively easy to get the wireless part right, because once he had calculated the number of coils he needed, all he had to do was 3D model the track for the copper to go in.

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Interview With A Printer

The Hackaday European tour continues, this time in Prague with Josef Průša (Google translate), core developer in the RepRap project, feature at all the Maker Faires and cons, and creator of his namesake, the Prusa Mendel and i3 printers.

[Prusa]’s involvement with the RepRap project started with a RepRap Mendel, the second iteration of RepRap hardware, but the first popular and easy to build version. [Jo] found the Mendel rather difficult to build, so he loaded OpenSCAD and started to design his own version of the hardware. This version became the de facto standard RepRap for a few years, with many inspired by and derivative printers making their way to hackerspaces and workshops around the world.

The first Prusa printer, derived from the RepRap Mendel.
The first Prusa printer, derived from the RepRap Mendel.

A few years ago, [Prusa] was one of the first to make a complete break with the traditional ‘threaded rod and nut’ construction of RepRaps with the introduction of the Prusa i3. This was the first model that had a metal plate as the frame, another feature that would be seen in dozens of other models. It’s not something that was without controversy, either; using a metal plate for the frame doesn’t allow for as much self-replication, something that’s a core value of the RepRap project. That didn’t matter to the community; the Prusa i3 or a similar design is the third most popular printer on 3Dhubs.

The first Prusa printer showing off its Makerbot heritage
The first Prusa printer showing off its Makerbot heritage

What’s the future of the Prusa name? There is an i4 in the works, and I’m pretty sure that’s all I can tell you. Someone already bought the Prusai4 domain, so there may be a name change.

In the interview below, [Prusa] goes over his involvement with the RepRap project, his business, what he considers to be the latest advances in 3D printing for the past year, what the worst things about the 3D printing scene is (it’s Kickstarter), the state of the RepRap project, and thoughts on SLS, DLP, and SLA printing technologies. Video below.

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Make Flexible PCBs with Your 3D Printer

The last few years have seen great strides in budget printed circuit board manufacturing. These days you can have boards made in a week for only a few dollars a square inch. Flexible PCBs still tend to be rather expensive though. [Mikey77] is changing that by making flex circuits at home with his 3D printer. [Mikey77] utilized one of the properties of Ninjaflex Thermoplastic Elastomer (TPE) filament – it sticks to bare copper!

The TPE filament acts as an etch resist, similar to methods using laser printer toner. For a substrate, [Mikey77] lists 3 options:

.004″ thick “Scissor cut” copper clad board from Electronics Goldmine

.002″ thick pure copper polyester taffeta fabric from lessEMF.com

<.001″ Pyralux material from Adafruit, which is one of the materials used to make professional flex PCBs.

A bit of spray adhesive will hold the Flex PCB down on the printer’s bed. The only issue is convincing the printer to print a few thousandths of an inch higher than the actual bed level. Rather than change the home position on his Z axis, [Mikey77] used AutoDesk 123D to create 3D PCB designs. Each of his .stl files has a “spacer bar”, which sits at the bed level. The actual tracks to be printed are in the air a few thousandths of an inch above the bed – exactly the thickness of the substrate material. The printer prints the spacer bar on the bed, then raises its Z height and prints on the flexible PCB material. We’re sure that forcing the printer to print in mid-air like this would cause some printer software to throw errors, but the system worked for [Mikey77] and his Makerbot.

Once the designs have been printed, the boards are etched with standard etching solutions such as ferric chloride. Be careful though – these thin substrates can etch much faster than regular PCB.

MakerBot Files Patents, Internet Goes Crazy

In the past month, a few patent applications from MakerBot were published, and like everything tangentially related to the prodigal son of the 3D printer world, the Internet arose in a clamor that would be comparable only to news that grumpy cat has died. That’s just an analogy, by the way. Grumpy cat is fine.

The first patent, titled, Three-dimensional printer with force detection was filed on October 29th, 2013. It describes a 3D printer with a sensor coupled to the hot end able to sense a contact force between the nozzle and build plate. It’s a rather clever idea that will allow any 3D printer to perform software calibration of the build plate, ensuring everything is printed on a nice, level surface. Interestingly, [Steve Graber] posted an extremely similar design of a bed leveling probe on October 6th, 2013. In [Steve]’s video, you can see his bed level probe doing just about everything the MakerBot patent claims, all while being uploaded to YouTube before the patent application.

When it rains it pours, and the Quick-release extruder patent application, filed on October 28, 2013, bears this out. It claims an extruder that includes, “a bistable lever including a mechanical linkage to the bearing, the bearing engaged with the drive gear when the bistable lever is in a first position and the bearing disengaged from the drive gear when the bistable lever is in a second position.” Simple enough, a lever with two positions, where one presses a bearing against a drive gear, and the other position disengages the bearing from a drive gear. Here’s something that was published on Thingiverse in 2011 that does the same thing. Hugely famous RepRap contributor [whosawhatsis] has weighed in on this as well.

It is important to note that these are patent applications. Nothing has been patented yet. The US Patent and Trademark Office does seem to have a lot of rubber stamps these days, so what is the average Internet denizen to do? Here are easy to follow, step-by-step instructions on how to notify the USPTO of prior art. Remember, just because prior art does not completely invalidate a patent application’s claims doesn’t mean you shouldn’t send it in. It is a patent examiner’s job to review the prior art.

So there you go. MakerBot applies for patents, people complain, but not to the USPTO. Highly relevant video and transcription below.

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Replicator 1 Receives a PID Controlled Heated Chamber

Replicator 1 PID Heated Enclosure

Improving 3D print quality is a bit of a black magic — there are tons of little tweaks you can do to your printer to help it, but in the end you’re just going to have to try everything. Adding a heated build enclosure however is one of those things almost guaranteed to improve the print quality of ABS parts!

And for good reason too — heated build enclosures are one of the outstanding “patented 3D printing technologies” — It’s why you don’t see any consumer printers with that feature. Anyway, [Bryan] just sent us his upgrade to his Makerbot Replicator 1, and it’s a pretty slick system. His goal was to add the heated enclosure to the printer as unobtrusively as possible — no need for people to think his printer is an even bigger fire hazard!

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Automated Bed Leveling For 3D Printers Is Now Solved

The latest and greatest feature for 3D printers – besides being closed source, having no meaningful technical specs, and being on track towards pulling in $10 Million on a Kickstarter – is automated bed leveling. This amazingly useful feature makes sure your prints have proper adhesion to the bed, reduce print errors, and put even inexpensive printers into the realm of extremely expensive professional machines. Automated bed leveling has been extremely hard to implement in the past, but now [Scottbee] has it figured out with a working prototype on his Makerbot Replicator 2X.

Earlier attempts at automated bed leveling used some sort of probe on the tool head to measure the build plate, calculate its flatness and orientation in space, and compensate for any tilt in software. [Scottbee]’s solution to the problem took a different tack: instead of trying to compensate for any odd orientation of the build surface in software, he’s simply making the bed level with a series of springs and cam locks.

[Scottbee]’s device levitates the build plate on three springs, and replaces the jack screws with three “gimballing pins” and pin locks. With the pin locks disengaged, the bed plate is pressed down with the printer’s nozzle. By moving the extruder across the build plate and locking the pins in place one by one, [Scottbee]’s device defines the plane of the build plate along three points. This makes the build platform parallel to the extruder nozzle, and also has a nice benefit of setting the distance from the build platform to the nozzle precisely with incredible repeatability.

The mechanics of locking the three gimballing pins in place  only requires a single DC gear motor, driven by an extra fan output on the Makerbot’s electronics. It’s simple, and with a bit of rework, it looks like most of the device could also be 3D printed.

An awful lot of RepRaps and 3D printers out there already use three points to attach the build plate to a frame. With a little bit of effort, this same technique could be ported and made a bit more generic than the Makerbot-based build seen above. It’s amazingly simple, and we can’t wait to see this applied to a normal RepRap.

Thanks [Josh] for the tip.