[Gavilan Steinman] just printed and assembled his own RepRap machine and filmed the process. This isn’t news but we found it very interesting to watch. He started with a RepStrap, a rapid-prototyping 3D printer that as built by hand instead of printed by a similar machine. This is the seminal step in the self-replicating process.

From there he prints an extruder head which improves the quality of the parts the RepStrap can produce. We then see time-lapse footage of the printing process for a Mendel unit, the second generation of RepRap machines. We’ve embedded the video after the break. It’s a great way to spend ten minutes on a Sunday afternoon.

[Ned] tipped us off about his project for a class at Carnegie Mellon. Utilizing a Denso 6-AOF robotic arm they have built a rapid prototyping machine that uses Lego as the building material. LDraw, the open standard Lego CAD program, is used to build a model which is then translated into MATLAB files that the robotic arm can use for placement commands. Right now pieces need to be placed on a template for the robot to find and pick up.

It’s great that Lego pieces are used because they are readily available and inexpensive, but this type of precision robot makes the project unattainable for most tinkerers. Still, the concept is interesting and we could see an end goal being a more widely available machine. It’s not too much of a leap to image a RepRap type machine that takes internal measurements of a circuit board and the components, calculates inside case dimensions, then builds a prototype enclosure from common Lego pieces.

Generation 2.0 of RepRap, the self replicating 3d printer, is approaching realization. Code named “Mendel”, the new design will be wedge shaped rather than a box which offers a few benefits. The overall design is smaller than the original RepRap but the printable area is larger. This means more functionality with less building material. With each new generation of this project the assembly gets easier and total parts price drops making the RepRap available to a much wider audience.

The RepRap blog has put forth some design specs, a picture of the assembled prototype, and has links for general assembly information (ZIP). We won’t see a finished version of this released for a few months but so far it looks like a big leap forward.

The RepRap project has been working on bringing 3D printing to the masses by creating a extrusion printer that can also make the majority of its own parts. For the most part, these print ABS or HDPE plastics which are strong and recyclable. In order to create these replicating printers, similar machines called RepStraps are built out of either laser-cut parts or machined elements. They are functionally equivalent to RepRap printers, but are not made of printed parts. [nophead] documented his RepStrap, HydraRaptor, that is based off a milling machine. He had already printed a set of RepRap parts, and he documented printing a second set. The machine worked for about 100 hours over the course of 2 weeks, printing about 1.5 kg of parts. He made a few adjustments, such as replacing ABS bearings with HDPE to reduce friction. The parts are for Factor e Farm so they can get started with 3D printing.

Related: RepRap pinch wheel extruder

[Rhys Jones] has been working with the RepRap team to develop a way to print circuit boards. The machine first prints the plastic substrate with channels for the metal to be deposited into. They adapted their pinch wheel feeder to work with solid core solder (flux creates a mess). The extruded solder’s specific heat isn’t hot enough to melt the plastic. They made a video (embedded below) of their test piece: an optical endstop. The team has also been experimenting with decoupling the feed mechanism from the extruder.

We’ve seen a lot of 3d printing lately, with the RepRap and Cupcake, both the fused deposition modeling type. We don’t often see the Inkjet method. This is a great example of one, built in someones home. Instead of laying down layers of molten plastic, he uses the inkjet system to deposit glue like substances into layers of plaster. This project is much higher resolution than the other two, as you can see in the video of it making an RC engine case below. He is currently rebuilding it to be even better and larger.

[thanks Luke]

What you see above is the culmination of [Zach Smith]‘s work building a pinch wheel style extruder for the RepRap. The current RepRap 3D printer uses a screw mechanism to push 3mm polymer filament into a heating barrel where it is melted and then extruded through a fine nozzle. [Zach]‘s new version uses a drive gear from SDP/SI mounted directly to the DC motor we saw him teardown earlier. He’s redesigned the carrier for the extruder as well. It’s now much lighter and has provisions for mounting current and future controller electronics along with a magnetic rotary encoder. In the last two days, he’s been doing real world testing. It’s been doing well, but he’s learning to do things like always using a full spool and not trying to run short lengths back to back.

Ponoko is an on-demand manufacturing service. You submit your design and they’ll cut it out of one of their many materials. The site is built so you can sell your products or designs directly. They recently took a major step with the introduction of Designmake Prime. It’s a monthly subscription based service with many benefits. It lets you submit DXFs for evaluation instead of their standard EPS or SVG. You can request any material you want and they’ll provide direct support. You also get priority in manufacturing queues. While they’ve always offered an à la carte service, this new move puts Ponoko directly in the role of a traditional manufacturer. Offering manufacturing as a service shows their intention of former a relationship with their customers, but at the an individual level, which most manufacturers can’t approach because of scale.

Ponoko first came to our attention when RepRap published an acrylic version of their machine.

[via Fabbaloo]

[Deviant Ollam], lockpicker and beverage cooling contest host, was recently in Vienna, presumably for DeepSec. While there, he stopped by the Metalab hackerspace and checked out their RepRap rapid prototyping machine. You can see video of his visit above. He had them construct a custom fitted cover for the flash of his point and shoot camera. That’s what we love about rapid prototyping. Many of the projects we cover here solve a particular problem, but would never be considered commercially viable enough to put into production. With the availability of rapid prototyping increasing, hackers can start moving toward producing even more complex objects specific to their needs with a finish closer to commercial products.

[via Fabbaloo]

The RepRap is a self-copying 3D printer. The project has published plans for creating a lasercut acrylic version of the device. They call it a RepStrap since once assembled it could produce printed plastic versions of the machine components, bootstrapping true RepRaps. The plans are available for Ponoko an on-demand product service, and it would cost ~$380 if you used their service. The plans are free, so you could get them manufactured by other means. [vik] is still putting together the assembly instructions. He hopes to have an all inclusive electronics kit at some point too. This is another great step towards putting desktop manufacturing within reach of everyone.

The RepRap project, which is a printer that can make components using rapid prototyping technology, and it is designed so that it can eventually self replicate. Has released a new breakout board for the Sanguino that provides access to all the pins as screw terminals. The Sanguino is an Arduino compatible board based on the ATmega644P chip. You can populate the full board with all the components and have a fully functional single board. You could populate only the screw terminals and plug your Sanguino, and use it as a breakout board as well. The board design is released on Google Code.

If you happen to be in Berlin on December 27th, you might want to sign up for Fabienne’s wifi detector hacking workshop at 23c3.