The term RepRap is fairly common and gets thrown around too often when generally talking about DIY 3D Printers. We must remember that the intent of the RepRap project “…is about making self-replicating machines…” and of course “…making them freely available for the benefit of everyone…“.
[MiniMadRyan] has recently designed a printer that could be considered the embodiment of the RepRap philosophy. He’s calling it the MapleMaker Mini V2. An extremely high percentage of the parts required to build this printer are, in fact, printable themselves. The frame pieces are printed, all of which can be printed on the printer thanks to the 6x8x6 inches print volume. The overall design is aesthetically pleasing, resembling that of a Lulzbot Mini.
The MapleMaker Mini V2 is self-replicating. The other part of the RepRap goal is to be free to the community. The design files are available on YouMagine and the assembly manual is better than those provided by most commercial companies. So if you’re looking to build a printer, be sure to add this one to your short list!
With a name like that how could we possibly pass up featuring this one? Truly a hack, this pancake making robot was built in under 24 hours. [Carter Hurd], [Ryan Niemo], and [David Frank] won the 2015 Ohio State University Makethon with the project.
The gantry runs on drawer sliders using belts from a RepRap. The motors themselves are DC with encoders. [Carter] tells us that since most 3D Printers are build on stepper motors this meant they had to scratch-build the control software but luckily were able to reuse PID software for the rest. Get this, the pump driving the pancake batter was pulled from a Keurig and a servo motor is used to kink the tubing, halting the flow. We are amused by the use of a Sriracha bottle as the nozzle.
It wasn’t just the printer being hacked together. The team also built an iPhone app that lets you draw your desired pattern and push it to the machine via WiFi.
Inspired yet? We are! If you’re anywhere near New York City you need to bring this kind of game to our Hackathon on May 2-3. One night, lots of fun, lots of food, and plenty of hardware. What can you accomplish?
Ah, you thought we were done with our coverage of the Midwest RepRap Festival, didn’t you? No, there’s still more, thanks to [Timothy Koscielny] sending in some digital assets that were required to put this post together. This time, it’s the RepRap roundtable with [Johnny Russell] from Ultimachine, [Shane Graber] from MakerJuice, [Lars Brubaker] from MatterHackers, [Sanjay Mortimer] from E3D-Online.
The first video covers the introductions for these very prominent 3D printer developers and their views on what future advances in 3D printers will be, the differences between Delta, Cartesian, and Polar bots (there aren’t many), and when resin printers will start to pick up.
In the Q&A session, the panel fielded a few questions from the audience. Questions included how to get people into 3D modeling, an amazing question dealing with what we should be making (with the implication that we’re only making stupid plastic trinkets), and what needs work to bring 3D printing to the masses.
Special thanks to [Casey Hendrickson] from ninety two point three WOWO for MC’ing the RepRap roundtable and to [Timothy Koscielny] for the audio work. This isn’t it, though: I still need to dump a bunch of pictures after the break.
The Midwest RepRap Festival is over – forever. This was the last one. Apparently enough people complained that Goshen, Indiana wasn’t in the midwest. The number of Dairy Queens I passed contradicts this, but whatever. Next year, there’s going to be a different con in Goshen. Same content, different name. If you have a suggestion, you know where to put it.
The Groot fail
Contaminated with masterbatch
The world’s largest 3D printed trash can. People were taking pictures of them standing next to it.
What the infill looks like on the PartDaddy
I promised the world’s largest 3D printed trash can, and I gave you the world’s largest 3D printed trash can. This gigantic orange vase was printed on the PartDaddy, SeeMeCNC’s 18-foot tall delta printer a few months ago at the NYC Maker Faire. I have been using this as a trash can in my basement since then, making me one of the only people who have their trash can on Wikipedia.
Speaking of the PartDaddy, this is what a fail looks like. The first PartDaddy print was a Groot, a 13-hour long print job. It was left running overnight, but it ran out of PLA pellets sometime around 4 in the morning. If you’re wondering what the black band is around the Groot’s face is, here’s the breakdown:
The PartDaddy sucks PLA pellets up from a trash can (that’s not 3D printed), and dispenses it into a hopper above the print head. This hopper was 3D printed on the PartDaddy, and there is still a little bit of colarant dust in there. When the PLA pellets run out, that dust is embedded in the extrusion. When you realize that masterbatch is only about 5% of the finished plastic, it doesn’t take much black dust to discolor a print.
Yes, this is a print fail that could have been fixed by having an all-night bash. A few other people left their printers running overnight including [The Great Fredini] and his Scan-A-Rama. This was a Rostock Max that had something wonky happen with the Bowden. There was filament everywhere.
How about some Star Wars droids? An R2 from the Droid Builder’s Club was there, but there was also the beginnings of a completely 3D printed Roger. While we’re on the subject of plastic robots that will fall apart at a moment’s notice, there was a K’NEX 3D printer. Yes, it’s made almost entirely out of K’NEX, and it did work at one time. Those orange parts sitting next to it? Those came out of the K’NEX printer. If you’re looking for the definitive RepStrap, there ‘ya go.
Roger Roger, or a B1 Battle Droid
Lincoln death mask in bronzefill. Patinaed with vinegar.
For the last few months, metal filaments – PLA with tiny particles of copper, brass, bronze, iron, or aluminum have been available. MRRF was the first place where you could see them all together. A few things of note: these filaments are heavy – the printed objects actually feel like they’re made out of metal. They’re actually metal, too: the iron-based filaments had a tiny bit of red corrosion, and the Lincoln death mask above was treated with acetic acid. These filaments are also expensive, around $100 for 1kg. Still, if you want to print something that will be around in 100 years, this is what you should get.
The most beautiful printer ever
MRRF should have had a contest for the best looking 3D printer at the show. A beautiful delta from Detroit Rock City would have won:
That white hexagon in the center is a ceramic PCB that I’m told cost an ungodly amount of money. Underneath the ceramic build plate, there’s a few Peltiers between the bed and the large copper heat sink. The heat sink is connected to the three risers by heat pipes, making the entire printer one gigantic heat sink. Why would anyone make such an amazing art deco printer? For this.
Because you can use Peltiers to heat and cool a bed, a little bit of GCode at the end of a print will cool the bed to below room temperature. If you do your design right, this means the print will just fall over when it’s done. When the print bed is cooling, you can actually hear the bond between the bed and print cracking. It’s beautiful, it’s cool, and I’m told this printer will make its way to hackaday.io soon.
There you go, the best and coolest from the last Midwest RepRap Festival ever. There will never be another one. It only needs a better name, and [John] at SeeMeCNC is great at coming up with names. Just ask what VIP is a backronym of.
As far as locations for the Midwest RepRap Festival go, it’s not exactly ideal. This is a feature, not a bug, and it means only the cool people come out to the event. There were a few people travelling thousands of miles across an ocean, just to show off some cool things they built.
Two Colors, One Nozzle
[Sanjay] and [Josh] from E3D came all the way from merry olde England to show off a few of their wares. The star of their show was the Cyclops extruder, a dual-extrusion hot end that’s two input, one output. Yes, two colors can come out of one nozzle.
If you see a printer advertised as being dual extrusion, what you’re going to get is two extruders and two hot ends. This is the kludgy way to do things – the elegant solution is to make two colors come out of one nozzle.
The guys from E3D were showing off a few prints from their Cyclops nozzle that does just that, including a black and red poison dart frog, and a blue and white octopus. The prints looked amazing, and exactly what you would expect from a two-color print.
Rumor has it the development of the Cyclops involved extruding two colors, freezing the nozzle, and putting it in the mill just to see how the colors mixed. I didn’t see those pictures, but there’s a lot of work that went into this hot end.
The extruder uses a normal stepper motor, but instead of the usual knurled or threaded feed wheel and bearing to push filament though, he’s using two counter-rotating feed wheels attached to a planetary gear system. That’s a lot of torque that doesn’t distort or strip the filament. When you consider all the weird filaments that are coming out – ninjaflex, and even 3D printable machinable wax filament, this is extremely interesting.
Even if your filament isn’t exactly 1.75 or 3mm in diameter, this setup will still reliably push plastic; there is a bolt that will move one of the feed wheels in and out 0.4mm.
[Martin] had a pair of his extruders hooked up to a strain gauge, and it’s strong enough to lift your printer off the table without stripping the filament. Here’s a video of that demo from the bondtech page.
It’s time once again to venture out to Goshen, Indiana for the Midwest RepRap Festival. It is the largest 3D printing con in the entire world where no one is trying to sell you anything. With a qualifier like that, it doesn’t have to be very big, but last year over 1,500 people showed up to the Elkhart county farm show complex and this year many more people are expected.
Of the expected attendees that are not specifically involved with 3D printing, I’m told [Ben Heck] will be there, along with someone from Adafruit and Make. The EFF might have a booth. A local radio station is doing a remote, and the servers at Wings, Etc. — one of the few area pubs — are going to clean up this weekend.
The event officially starts at 4:00pm today, Friday, March 20th. If you won’t be going the entire weekend, I’d suggest showing up on Saturday or Sunday. There will be far too many people there, and I’m slightly agoraphobic. We’ll be posting updates from the MRRF later on.
Every filament-based 3D printer you’ll find today heats plastic with resistive heaters – either heater cartridges or big ‘ol power resistors. It’s efficient, but that will only get you so far. Given these heaters can suck down only so many Watts, they can only heat up so fast. That’s a problem, and if you’re trying to make a fast printer, it’s also a limitation.
Instead of dumping 12 or 24 VDC into a resistive heater, induction heaters passes high-frequency AC through a wire that’s inductively coupled to a core. It’s also very efficient, but it’s also very fast. No high-temperature insulation is required, and if it’s designed right, there’s less thermal mass. All great properties for fast heating of plastic.
A few years ago, [SB] over on the RepRap blog designed an induction heater for a Master’s project. The hot end was a normal brass nozzle attached to a mild steel sleeve. A laminated core was attached to the hot end, and an induction coil wrapped around the core. It worked, but there wasn’t any real progress for turning this into a proper nozzle and hot end. It was, after all, just a project.
Finally, after several years, people are squirting plastic out of an induction heated nozzle. [Z], or [Bulent Unalmis], posted a project to the RepRap forums where he is extruding plastic that has been heated with an induction heater. It’s a direct drive system, and mechanically, it’s a simpler system than the fancy hot ends we’re using now.
Electronically, it’s much more complex. While the electronics for a resistive heater are just a beefy power supply and a MOSFET, [Z] is using 160 kHz AC at 30 V. That’s a much more difficult circuit to stuff on a printer controller board.
This could be viewed as just a way of getting around the common 24V limitation of common controller boards; shove more power into a resistor, and it’s going to heat faster. This may not be the answer to hot ends that heat up quicker, but at the very least it’s a very neat project, and something we’d like to see more of.
You can see [Z]’s video demo of his inductive hot end below. Thanks [Matt] for the tip.