Josef Prusa: Multi Material Extruders for Amazing Color Prints

The Prusa i3 Mk 2 is the hotness in consumer-grade, quality 3D printing right now. And things just keep getting more interesting. We caught up with Josef Průša at Maker Faire Bay Area this weekend to see the multi-material extruder in its final form. It’s an upgrade to the Mk 2 which allows a single hot end to print in four different materials, be it different colors or different types of filament.

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Hackaday Links: April 2, 2017

Toorcamp registration is open. It’s June 20-24th on Orcas Island, Washington.

Hey, you. The guy still using Mentor Graphics. Yeah, you. Siemens has acquired Mentor Graphics.

CNC knitting machines are incredibly complicated but exceptionally cool. Until now, most CNC knitting machines are actually conversions of commercial machines. Beginning with [Travis Goodspeed] and  [Fabienne Serriere] hack of a knitting machine, [Becky Stern]’s efforts, and the Knitic project, these knitting machines are really just brain transplants of old Brother knitting machines. A few of the folks from the OpenKnit project have been working to change this, and now they’re ready for production. Kniterate is a project on Kickstarter that’s a modern knitting machine, and basically a 2D woolen printer. This is an expensive machine at about $4500, but if you’ve ever seen the inside of one of these knitting machines, you’ll know building one of these things from scratch is challenging.

There was a time when a Macintosh computer could play games. Yes, I know this sounds bizarre, but you could play SimCity 2000, Diablo, and LucasArts adventure games on a machine coming out of Cupertino. [Novaspirit] wanted to relive his childhood, so he set up a Mac OS 7 emulator on a Raspberry Pi. He’s using Minivmac, beginning with an install of OS 7.1, upgrading that to 7.5.3, then upgrading that to 7.5.5. It should be noted the utility of the upgrade to 7.5.5 is questionable — the only real changes from 7.5.3  to 7.5.5 are improved virtual memory support (just change some emulator settings to get around that) and networking support (which is difficult on an emulator). If you’re going to upgrade to 7.5.5, just upgrade to 8.1 instead.

It’s getting warmer in the northern hemisphere, and you know what that means: people building swamp coolers. And you know what that means: people arguing about the thermodynamics of swamp coolers. We love these builds, so if you have a swamp cooler send it on in to the tip line.

The Prusa edition of Slic3r is out. The improvements? It’s not a single core app anymore (!), so slicing is faster. It’s got that neat variable layer slicing. Check out all the features.

It takes at least a week to delete your Facebook account. In the meantime, you can lawyer up and hit the gym. Additionally, we’re not really sure Facebook actually deletes your profile when you disable your account. Robots to the rescue. [anerdev] built a robot to delete all his content from Facebook. It’s a pair of servos with touchpad-sensitive pens. Add an Arduino, and you have a Facebook deleting machine.

Hands On With Variable Layer Height

3D printers are an exercise in compromise. Generally, you don’t want a lot of mass on your tool head, as that can lead to ringing and other mechanical artifacts on your print. However, direct drive extruders are better for many filaments, and the decision on what printer to build ultimately comes down to a choice between speed, build area, and the ability to print in exotic filaments.

Even in slicing a 3D model, a 3D printing enthusiast must balance the quality of a print versus how long the print will take to squirt out of a nozzle. Now, just about any printer can produce fantastic models at a very high layer height, but no one wants to wait several days for the print to finish.

This balance between print time and print quality has, for the last few years, been completely ignored. One of the best solutions to this we’ve seen is variable layer height slicing. Basically, if you’re printing something without much detail, you don’t need small layers in your 3D print. Think of it as printing the neck of a bust at 0.3mm layer height, and the face at 0.1mm.

Yes, there were a few papers from a decade ago laying the conceptual foundations of variable layer height slicing. 3D printers weren’t exactly common back then, though. Recently, Autodesk’s Integrated Additive Manufacturing Team released Varislice for automatic generation of variable layer heights on a 3D printed object. So far, though, there’s no good automated solution for variable layer height slicing, and the tools for manual configuration of variable layer height slicing are terrible.

For the past few months, Prusa Research has been working on their own edition of Slic3r that includes an easy to use interface for variable layer height slicing. This version of Slic3r was just released, and now it’s time for the hands-on. Does variable layer height slicing work?

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Where There’s Smoke, There’s a Knockoff 3D Printer

These days, it’s possible to buy clones of popular 3D printers from China for satisfyingly low prices. As always, you get what you pay for, and while usable, often they require some modification to reach their full potential. [g3ggo] recently laid down €270 for a clone of the Prusa i3 by Geeetech, knowing it would require some modifications for safety and performance.

First on the bill was a wobbly Z-axis, which was dealt with by printing some new parts designed to fix this issue which have already been developed by the community. Forums are your friend here – often an enterprising user will have already developed fixes for the most common issues, and if they haven’t, you can always step up to be the hero yourself. There was a darker problem lurking inside, though.

[g3ggo] began to wonder why the MOSFETs for the hot end were running so hot. It turned out to be an issue of gate drive – the FETs were only being driven with 5V, which for the given part, wasn’t enough to reach its lowest R_DS(on) and thus was causing the overheating issue. It gets worse, though – the heatsinks on the MOSFETs were bolted on directly without insulation, and sitting fractions of a millimeter above traces on the PCB. Unfortunately, with a small scratch to the soldermask, this caused a short circuit, destroying the hot end and MOSFETs and narrowly avoiding a fire. This is why you never leave 3D printers unattended.

The fix? Replacing the MOSFETs with a part that could deal with a 5V gate drive was the first step, followed by using insulating pads & glue to stop the heatsinks contacting the PCB. Now with the cooler running MOSFETs, there’s less chance of fire, and the mainboard’s cooling fan isn’t even required anymore. Overall, for a small investment in time and parts, [g3ggo] now has a useful 3D printer and learned something along the way. Solid effort!

Hackaday Links: December 4, 2016

The Chaos Communication Congress is growing! Actually, it’s not, but there may be an ‘overflow venue’ for everyone who didn’t get a ticket. There’s a slack up for people who didn’t get a ticket to 33C3 but would still like to rent a venue, set up some tables, stream some videos, and generally have a good time.

Need to test a lot of batteries? Have one of those magnetic parts tray/dish things sitting around? This is freakin’ brilliant. Put your batteries vertically in a metal dish, clip one lead of a meter to the dish and probe each battery with the other lead of your meter.

Pravda reports the USS Zumwalt and HMS Duncan – the most technologically advanced ships in the US and Royal Navies – have turned into, ‘useless tin cans due to China’, with ‘Microchips made in China putting the vessels out of action’. Again, Pravda reports this, so don’t worry. In other news, someone found a few USB drives in a parking lot in Norfolk, Virginia.

Here’s how discourse goes on the Internet. Someone does something. Everyone says it’s stupid. We wait a few days or weeks. Someone posts something on Medium telling everyone it’s actually okay. Public opinion is muddled until the actual issue being discussed is rendered technologically irrelevant. For the newest MacBook Pro, we’re currently at stage 3 and ‘it’s kind of great for hackers’. Now if only we knew how to make USB-C ports work with microcontrollers…

If you have a Prusa i3, here’s a free gift: a Spitfire. The files to print a remote control, 973mm Spitfire Mk XVI are now free for Prusa i3 and i3 Mk 2 owners. Why? Because it’s cool, duh, and [Stephan Dokupil] and [Patrik Svida], the guys behind the Spitfire and other 3D printed RC planes, are also in Czech. Now all we need are Czech roundel stickers.

Hackaday Links: November 27, 2016

[Prusa]’s business is doing great. This year, he released the Prusa i3 Mk. 2, a four color upgrade to the printer, and sales are through the roof. There’s just one problem: Paypal just locked his funds. Prusa is turning away from Paypal and given Paypal’s history, this will eventually be worked out. Be warned, though: don’t use Paypal for your hardware business. We’ve seen this same story played out too many times before.

Those millennials are always on their phones. How do you get rid of that distraction? Airplane mode? No, that’s stupid. Put those phones in a metal box. It’s the exact same thing as airplane mode – which is free – but this extra special metal box costs $45 and ships in March. Is this metal box different from any other metal box, like a cookie tin, perhaps? Probably not.

Nothing to see here, folks.

The holidays are here, and it’s time for Cards Against Humanity to do something stupid with other people’s money. This year, they’re throwing money into a hole. No, really. People are contributing money to dig a gigantic hole. There’s a livestream of the digging. Five dollars lets the dig continue for another few seconds. Join in on the holiday spirit: throw your money into a hole.

You don’t want to throw your money into a hole? Buy some stuff on Tindie! There’s robots, CNC controllers, servo drivers, MIDI arpeggiators, USB testers, power supplies, blinky glowy things, and retro gaming stuff. Go plug your Raspberry Pi into some of these gizmos.

The Mechaduino is a board that clips onto a ubiquitous NEMA stepper motor to turn it into a servo motor.  It won 5th place in the Hackaday Prize last month, and we can’t wait to see it integrated into a closed-loop 3D printer. [Chris] came up with an Ethernet-enabled servo-stepper conversion, and now it’s a project on Kickstarter. Of course, you can buy a Mechaduino right now, making the future of stepper motor-controlled desktop CNC very interesting.

Individually addressable RGB LEDs exist, and we’re waiting for Clark Griswold to electrify his house in red, green, and blue. Until then, [Michel built a holiday ornament loaded up with 16 WS2812b LEDs. The star features caps and diodes to make everything work as it should and requires only three wires per star.

Maker Faire Multicolor and Multi Material 3D Printing

The next frontier of desktop 3D printing is multi-material and multi-color prints. Right now, you can buy a dual toolhead for a Lulzbot, and dual toolheads from other companies exist, although they are a bit rare. In the next few years, we’re going to see a lot of printers able to print dissolvable supports and full-color 3D printers.

Printing in more than one color is almost here, but that doesn’t mean we’re on the cusp of a complete revolution. Multi-material printing is lagging a little bit behind; you’ll be able to print two colors of PLA next year, but printing an object in PLA and ABS is going to be a bit tricky. Printing something in PLA and nylon will be very hard. Color mixing, likewise, will be tricky. We can do it, the tools are getting there, but think of this year as a preview of what we’ll be doing in five years.

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