Infill Injection Experiment Makes Stronger Parts

February 25, 2025 by Donald Papp 28 Comments

[JanTec Engineering] was fascinated by the idea of using a 3D printer’s hot end to inject voids and channels in the infill with molten plastic, leading to stronger prints without the need to insert hardware or anything else. Inspiration came from two similar ideas: z-pinning which creates hollow vertical channels that act as reinforcements when filled with molten plastic by the hot end, and VoxelFill (patented by AIM3D) which does the same, but with cavities that are not uniform for better strength in different directions. Craving details? You can read the paper on z-pinning, and watch VoxelFill in (simulated) action or browse the VoxelFill patent.

With a prominent disclaimer that his independent experiments are not a copy of VoxelFill nor are they performing or implying patent infringement, [JanTec] goes on to use a lot of custom G-code (and suffers many messy failures) to perform some experiments and share what he learned.

Using an airbrush nozzle as a nozzle extension gains about 4 mm of extra reach.

One big finding is that one can’t simply have an empty cylinder inside the print and expect to fill it all up in one go. Molten plastic begins to cool immediately after leaving a 3D printer’s nozzle, and won’t make it very far down a deep hole before it cools and hardens. One needs to fill a cavity periodically rather than all in one go. And it’s better to fill it from the bottom-up rather than from the top-down.

He got better performance by modifying his 3D printer’s hot end with an airbrush nozzle, which gave about 4 mm of extra length to work with. This extra long nozzle could reach down further into cavities, and fill them from the bottom-up for better results. Performing the infill injection at higher temperatures helped fill the cavities more fully, as well.

Another thing learned is that dumping a lot of molten plastic into a 3D print risks deforming the print because the injected infill brings a lot of heat with it. This can be mitigated by printing the object with more perimeters and a denser infill so that there’s more mass to deal with the added heat, but it’s still a bit of a trouble point.

[JanTec] put his testing hardware to use and found that parts with infill injection were noticeably more impact resistant than without. But when it came to stiffness, an infill injected part resisted bending only a little better than a part without, probably because the test part is very short and the filled cavities can’t really shine in that configuration.

These are just preliminary results, but got him thinking there are maybe there are possibilities with injecting materials other than the one being used to print the object itself. Would a part resist bending more if it were infill injected with carbon-fibre filament? We hope he does some follow-up experiments; we’d love to see the results.

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Homebrew CPU Gets A Beautiful Rotating Cube Demo

February 19, 2025 by Donald Papp 10 Comments

[James Sharman] designed and built his own 8-bit computer from scratch using TTL logic chips, including a VGA adapter, and you can watch it run a glorious rotating cube demo in the video below.

The rotating cube is the product of roughly 3,500 lines of custom assembly code and looks fantastic, running at 30 frames per second with shading effects from multiple light sources. Great results considering the computing power of his system is roughly on par with vintage 8-bit home computers, and the graphics capabilities are limited. [James]’s computer uses a tile map instead of a frame buffer, so getting 3D content rendered was a challenge.

The video is about 20 seconds of demo followed by a detailed technical discussion on how exactly one implements everything required for a 3D cube, from basic math to optimization. If a deep dive into that sort of thing is up your alley, give it a watch!

We’ve featured [James]’ fascinating work on his homebrew computer before. Here’s more detail on his custom VGA adapter, and his best shot at making it (kinda) run DOOM.

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MIT Demonstrates Fully 3D Printed, Active Electronic Components

February 19, 2025 by Donald Papp 26 Comments

One can 3D print with conductive filament, and therefore plausibly create passive components like resistors. But what about active components, which typically require semiconductors? Researchers at MIT demonstrate working concepts for a resettable fuse and logic gates, completely 3D printed and semiconductor-free.

Now just to be absolutely clear — these are still just proofs of concept. To say they are big and perform poorly compared to their semiconductor equivalents would be an understatement. But they do work, and they are 100% 3D printed active electronic components, using commercially-available filament.

How does one make a working resettable fuse and transistor out of such stuff? By harnessing thermal expansion, essentially.

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Belfry OpenSCAD Library (BOSL2) Brings Useful Parts And Tools Aplenty

February 18, 2025 by Donald Papp 16 Comments

OpenSCAD has a lot of fans around these parts — if you’re unaware, it’s essentially a code-based way of designing 3D models. Instead of drawing them up in a CAD program, one writes a script that defines the required geometry. All that is made a little easier with the Belfry OpenSCAD Library (BOSL2).

Designing a part like this is a cinch with BOSL2.

BOSL2 has an extensive library of base shapes, advanced functions for manipulating models, and some really nifty tools for creating attachment points on parts and aligning components with one another. If that sounds handy for designing useful objects, you’re in for even more of a treat when you see their functions for gears, hinges, screws, and more.

There’s even one that covers bottle necks and caps. (Those are all standardized by the way, so it’s never been easier to interface to existing bottles or caps in a project.)

OpenSCAD really is very versatile software. It powers useful tools like this screw, washer, and nut generator as well as having more unusual applications like a procedural terrain generator. It’s free, so if you’ve never looked into it, check it out!

New Documentary Details Ventilator Development Efforts During COVID

February 12, 2025 by Donald Papp 19 Comments

What would it be like to have to design and build a ventilator, suitable for clinical use, in ten days? One that could be built entirely from locally-sourced parts, and kept oxygen waste to a minimum? This is the challenge [John Dingley] and many others faced at the start of COVID-19 pandemic when very little was known for certain.

Back then it was not even known if a vaccine was possible, or how bad it would ultimately get. But it was known that hospitalized patients could not breathe without a ventilator, and based on projections it was possible that the UK as a whole could need as many as 30,000 ventilators within eight weeks. In this worst-case scenario the only option would be to build them locally, and towards that end groups were approached to design and build a ventilator, suitable for clinical use, in just ten days.

A ventilator suitable for use on a patient with an infectious disease has a number of design constraints, even before taking into account the need to use only domestically-sourced parts.

[John] decided to create a documentary called Breathe For Me: Building Ventilators for a COVID Apocalypse, not just to tell the stories of his group and others, but also as a snapshot of what things were like at that time. In short it was challenging, exhausting, occasionally frustrating, but also rewarding to be able to actually deliver a workable solution.

In the end, building tens of thousands of ventilators locally wasn’t required. But [John] felt that the whole experience was a pretty unique situation and a remarkable engineering challenge for him, his team, and many others. He decided to do what he could to document it, a task he approached with a typical hacker spirit: by watching and reading tutorials on everything from conducting and filming interviews to how to use editing software before deciding to just roll up his sleeves and go for it.

We’re very glad he did, and the effort reminds us somewhat of the book IGNITION! which aimed to record a history of technical development that would otherwise have simply disappeared from living memory.

You can watch Breathe for Me just below the page break, and there’s additional information about the film if you’d like to know a bit more. And if you are thinking the name [John Dingley] sounds familiar, that’s probably because we have featured his work — mainly on self-balancing personal electric vehicles — quite a few times in the past.

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Make A Secret File Stash In The Slack Space

February 10, 2025 by Donald Papp 15 Comments

Disk space is allocated in clusters of a certain size. When a file is written to disk and the file size is smaller than the cluster(s) allocated for it, there is an unused portion of varying size between the end of the file’s data and the end of the allocated clusters. This unused space is the slack space, it’s perfectly normal, and [Zachary Parish] had an idea to write a tool to hide data in it.

The demo uses a usb drive, using the slack space from decoy files to read and write data.

[Zachary]’s tool is in Python and can map available slack space and perform read and write operations on it, treating the disparate locations as a single unified whole in which to store arbitrary files. A little tar and gzip even helps makes things more efficient in the process.

There’s a whole demo implemented on Linux using a usb drive with some decoy files to maximize the slack space, and you can watch it in action in the video embedded below. It’s certainly more practical than hiding data in a podcast!

Note that this is just a demo of the concept. The approach does have potential for handling secret data, but [Zachary] points out that there are — from a serious data forensics point of view– a number of shortcomings in its current form. For example, the way the tool currently structures and handles data makes it quite obvious that something is going on in the slack space.

[Zachary] created this a few years ago and has some ideas about how to address those shortcomings and evolve the tool, so if you have ideas of your own or just want to try it out, the slack_hider GitHub repository is where you want to go.

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Make Custom Shirts With A 3D Print, Just Add Bleach

February 10, 2025 by Donald Papp 38 Comments

Bleach is a handy way to mark fabrics, and it turns out that combining bleach with a 3D-printed design is an awfully quick-working and effective way to stamp a design onto a shirt.

Plain PLA stamp with bleach gives a slightly distressed look to this design.

While conceptually simple, the details make the difference. Spraying bleach onto the stamp surface helps get even coverage, and having the stamp facing “up” and lowering the shirt onto the stamp helps prevent bleach from running where it shouldn’t. Prompt application of hot air with a heat gun (followed by neutralizing or flushing any remaining bleach by rinsing in plenty of cold water) helps keep the edges of the design clean and sharp.

We wondered if combining techniques with some of the tips on how to 3D print ink stamps would yield even better results. For instance, we notice the PLA stamp (used to make the design in the images here) produces sharp lines with a slightly “eroded” look overall. This is very much like the result of inking with a stamp printed in PLA. With a stamp printed in flex filament, inking gives much more even results, and we suspect the same might be true for bleach.

Of course, don’t forget that it’s possible to 3D print directly onto fabric if you want your designs to be a little more controlled (and possibly in multiple colors). Or, try silkscreening. Who knew there were so many options for putting designs onto shirts? If you try it out and learn anything, let us know by sending in a tip!

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