Improving Mister Screamer; An 80 Decibel Filament Alarm

June 7, 2017 by Donald Papp 46 Comments

I created a prototype 3D printer filament alarm that worked, but the process also brought some new problems and issues to the surface that I hadn’t foreseen when I first started. Today I’m going to dive further into the prototyping process to gain some insight on designing for a well-specified problem. What I came up with is an easy to build pendant that passively hangs from the filament and alerts you if anything about that changes.

I began with a need to know when my 3D printer was out of filament, so that I could drop whatever I was doing and insert a new spool of filament right up against the end of the previous spool. By doing this within four minutes of the filament running out, printing very large jobs could continue uninterrupted. The device I designed was called Mister Screamer.

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Formlabs Announces A Desktop SLS 3D Printer

June 5, 2017 by Donald Papp 30 Comments

Formlabs have just announced the Fuse 1 — a selective laser sintering (SLS) 3D printer that creates parts out of nylon. Formlabs is best known for their Form series of resin-based SLA 3D printers, and this represents a very different direction.

SLS printers, which use a laser to sinter together models out of a powder-based material, are not new but have so far remained the domain of Serious Commercial Use. To our knowledge, this is the first time an actual SLS printer is being made available to the prosumer market. At just under 10k USD it’s definitely the upper end of the prosumer market, but it’s certainly cheaper than the alternatives.

The announcement is pretty light on details, but they are reserving units for a $1000 deposit. A few things we can throw in about the benefits of SLS: it’s powder which is nicer to clean up than resin printers, and parts should not require any kind of curing. The process also requires no support material as the uncured powder will support any layers being cured above it. The Fuse 1’s build chamber is 165 x 165 x 320 mm, and can be packed full of parts to make full use of the volume.

In the past we saw a detailed teardown of the Form 2 which revealed excellent workmanship and attention to detail. Let’s hope the same remains true of Formlabs’ newest offering.

Watch The ClearWalker Light Up And Dip Its Toes

June 1, 2017 by Donald Papp 10 Comments

[Jeremy Cook]’s latest take on the Strandbeest, the ClearWalker, is ready to roll! He’s been at work on this project for a while, and walks us through the electronics and control system as well as final assembly tweaks. The ClearWalker is fully controllable and includes a pan and tilt camera as well as programmable LED segments, and even a tail.

When we last saw [Jeremy] at work on this design, it wasn’t yet functional. He showed us all the important design and assembly details that went into creating a motorized polycarbonate version of [Theo Jansen’s] classic Strandbeest design; there’s far more to the process than simply scaling parts up or down. Happily, [Jeremy] is able to show off the crystal clear beauty in his photo gallery as well as a new video, embedded below.

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Practical Enclosure Design, Optimized For 3D Printing

May 24, 2017 by Donald Papp 37 Comments

[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.

Hackaday Prize Entry: Rangefinder + Camera = SmartZoom

May 23, 2017 by Donald Papp 17 Comments

The interesting thing about submissions for The Hackaday Prize is seeing unusual projects and concepts that might not otherwise pop up. [ken conrad] has a curious but thoughtfully designed idea for Raspberry Pi-based SmartZoom Imaging that uses a Pi Zero and camera plus some laser emitters to create a device with a very specific capability: a camera that constantly and dynamically resizes the image make the subject appear consistently framed and sized, regardless of its distance from the lens. The idea brings together two separate functions: rangefinding and automated zooming and re-sampling of the camera image.

The Raspberry Pi uses the camera board plus some forward-pointing laser dots as a rangefinder; as long as at least two laser dots are visible on the subject, the distance between the device and the subject can be calculated. The Pi then uses the knowledge of how near or far the subject is to present a final image whose zoom level has been adjusted to match (and offset) the range of the subject from the camera, in effect canceling out the way an object appears larger or smaller based on distance.

We’ve seen visible laser dots as the basis of rangefinding before, but never tied into a zoom function. Doubtlessly, [ken conrad] will update his project with some example applications, but in the meantime we’re left wondering: is there a concrete, practical use case for this unusual device? We have no idea, but we’d certainly have fun trying to find one.

JeVois Machine Vision Camera Nails Demo Mode

May 17, 2017 by Donald Papp 31 Comments

JeVois is a small, open-source, smart machine vision camera that was funded on Kickstarter in early 2017. I backed it because cameras that embed machine vision elements are steadily growing more capable, and JeVois boasts an impressive range of features. It runs embedded Linux and can process video at high frame rates using OpenCV algorithms. It can run standalone, or as a USB camera streaming raw or pre-processed video to a host computer for further action. In either case it can communicate to (and be controlled by) other devices via serial port.

But none of that is what really struck me about the camera when I received my unit. What really stood out was the demo mode. The team behind JeVois nailed an effective demo mode for a complex device. That didn’t happen by accident, and the results are worth sharing.

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VR Mech’s Missing Link: The Phone In Your Pocket

April 26, 2017 by Donald Papp 10 Comments

In the process of making a homemade Mech Combat game that features robot-like piloted tanks capable of turning the cockpit independent of the direction of movement, [Florian] realized that while the concept was intuitive to humans, implementing it in a VR game had challenges. In short, when the body perceives movement but doesn’t feel the expected acceleration and momentum, motion sickness can result. A cockpit view that changes independently of forward motion exacerbates the issue.

To address this, [Florian] wanted to use a swivel chair to represent turning the Mech’s “hips”. This would control direction of travel and help provide important physical feedback. He was considering a hardware encoder for the chair when he realized he already had one in his pocket: his iPhone.

By making an HTML page that accesses the smartphone’s Orientation API, no app install was needed to send the phone’s orientation to his game via a WebSocket in Unity. He physically swivels his chair to steer and is free to look around using the VR headset, separate from the direction of travel. Want to try it for yourself? Get it from [Florian]’s GitHub repository.

A video is embedded below, but if you’re interested in details be sure to also check out [Florian]’s summary of insights and methods for avoiding motion sickness in a VR Mech cockpit.

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