Best Practices For FDM Printing

If you’ve been designing parts for 3D printing, you probably have some tricks and standards for your designs. [Rahix] decided to write out a well-thought-out set of design rules for FDM prints, and we can all benefit.

One of the things we liked about the list is that it’s written in a way that explains everything. Every so often, there’s a box with a summarized rule for that topic. At the end, there’s a list of all the rules. The rules are also in categories, including part strength, tolerance, optimization, integration, machine elements, appearance, and vase mode.

For example, section two deals with tolerance and finish. So, rule R2.8 says, “Do not use circular holes for interference fits. Use hexagon or square holes instead.”

We also appreciate that [Rahix] touched on some of the counter-intuitive aspects of designing for FDM printing. For example, you might think adding voids in your part will reduce the filament and time required to print it, but in many cases it can have the opposite effect.

Some of these — maybe even most of these — won’t surprise you, but you still might take away a tidbit or two. But having it all down in a checklist and then the ability to scroll up and find the rationale for the rule is great.

Do you have any rules you’d add? Or change? Let us know. Meanwhile, we were eyeing our favorites about adding machine elements to prints.

“Man And Machine” Vs “Man Vs Machine”

Every time we end up talking about 3D printers, Al Williams starts off on how bad he is in a machine shop. I’m absolutely sure that he’s exaggerating, but the gist is that he’s much happier to work on stuff in CAD and let the machine take care of the precision and fine physical details. I’m like that too, but with me, it’s the artwork.

I can’t draw to save my life, but once I get it into digital form, I’m pretty good at manipulating images. And then I couldn’t copy that out into the real world, but that’s what the laser cutter is for, right? So the gameplan for this year’s Mother’s Day gift (reminder!) is three-way. I do the physical design, my son does the artwork, we combine them in FreeCAD and then hand it off to the machine. Everyone is playing to their strengths.

So why does it feel a little like cheating to just laser-cut out a present? I’m not honestly sure. My grandfather was a trained architectural draftsman before he let his artistic side run wild and went off to design jewellery. He could draw a nearly perfect circle with nothing more than a pencil, but he also used a French curve set, a pantograph, and a rolling architect’s ruler when they were called for. He had his tools too, and I bet he’d see the equivalence in mine.

People have used tools since the stone age, and the people who master their tools transcend them, and produce work where the “human” shines through despite having traced a curve or having passed the Gcode off to the cutter. If you doubt this, I’ll remind you of the technological feat that is the piano, with which people nonetheless produce music that doesn’t make you think of the hammers or of the tremendous cast metal frame. The tech disappears into the creation.

I’m sure there’s a parable here for our modern use of AI too, but I’ve got a Mother’s Day present to finish.

PoE-powered GPIB Adapter With Ethernet And USB-C Support

In the world of (expensive) lab test equipment the GPIB (general purpose interface bus) connection is hard to avoid if you want any kind of automation, but nobody likes wrangling with the bulky cables and compatibility issues when they can just use Ethernet instead. Here [Chris]’s Ethernet-GPIB adapter provides an easy solution, with both Power over Ethernet (PoE) and USB-C power options. Although commercial adapters already exist, these are rather pricey at ~$500.

Features of this adapter include a BOM total of <$50, with power provided either via PoE (802.3af) or USB-C (5V-only). The MCU is an ATmega4809 with the Ethernet side using a Wiznet W5500 SPI Ethernet controller. There is also a serial interface (provided by a CH340X USB-UART adapter), with the firmware based on the AR488 project.

The adapter supports both the VXI-11.2 and Prologix protocols, though not at the same time (due to ROM size limitations). All design documents are available via the GitHub repository, with the author also selling assembled adapters and providing support primarily via the EEVBlog forums.

Mongoose Wizard new project dialog.

Web Dashboard And OTA Updates For The ESP32

Today we are happy to present a web-based GUI for making a web-based GUI! If you’re a programmer then web front-end development might not be your bag. But a web-based graphical user interface (GUI) for administration and reporting for your microcontroller device can look very professional and be super useful. The Mongoose Wizard can help you develop a device dashboard for your ESP32-based project.

In this article (and associated video) the Mongoose developers run you through how to get started with their technology. They help you get your development environment set up, create your dashboard layout, add a dashboard page, add a device settings page, add an over-the-air (OTA) firmware update page, build and test the firmware, and attach the user-interface controls to the hardware. The generated firmware includes an embedded web server for serving your dashboard and delivering its REST interface, pretty handy.

You will find no end of ESP32-based projects here at Hackaday which you could potentially integrate with Mongoose. We think the OTA support is an excellent feature to have, but of course there are other ways of supporting that functionality.

Continue reading “Web Dashboard And OTA Updates For The ESP32”

The Apple II MouseCard (Credit: AppleLogic.org)

The Apple II MouseCard IRQ Is Synced To Vertical Blanking After All

Recently [Colin Leroy-Mira] found himself slipping into a bit of a rabbit hole while investigating why only under Apple II MAME emulation there was a lot of flickering when using the (emulated) Apple II MouseCard. This issue could not be reproduced on real (PAL or NTSC) hardware. The answer all comes down to how the card synchronizes with the system’s vertical blanking (VBL) while drawing to the screen.

The Apple II MouseCard is one of the many peripheral cards produced for the system, originally bundled with a version of MacPaint for the Apple II. While not a super popular card at the time, it nevertheless got used by other software despite this Apple system still being based around a command line interface.

According to the card’s documentation the interrupt call (IRQ) can be set to 50 or 60 Hz to match the local standard. Confusingly, certain knowledgeable people told him that the card could not be synced to the VBL as it had no knowledge of this. As covered in the article and associated MAME issue ticket, it turns out that the card is very much synced with the VBL exactly as described in The Friendly Manual, with the card’s firmware being run by the system’s CPU, which informs the card of synchronization events.

The Nuclear War You Didn’t Notice

We always enjoy [The History Guy], and we wish he’d do more history of science and technology. But when he does, he always delivers! His latest video, which you can see below, focuses on the Cold War pursuit of creating transfermium elements. That is, the discovery of elements that appear above fermium using advanced techniques like cyclotrons.

There was a brief history of scientists producing unnatural elements. The two leaders in this work were a Soviet lab, the Joint Institute of Nuclear Research, and a US lab at Berkeley.

Continue reading “The Nuclear War You Didn’t Notice”

Antique Mill Satisfies Food Cravings

Everyone knows what its like to get a hankering for a specific food. In [Attoparsec]’s case, he wanted waffles. Not any waffles would do, though; he needed waffles in the form of a labyrinth. Those don’t exist, so he had to machine his own waffle maker.

Antique pantograph mill
When computers were the size of rooms, these stood in where we’d use CNC today.

Most of us would have run this off on a CNC, but [Attoparsec] isn’t into CNCing–manual machining is his hobby, and he’s not interested in getting into another one, no matter how much more productive he admits it might make him. We can respect that. After a bit of brain sweat thinking of different ways to cut out the labyrinth shape, he has the opportunity to pick up an antique Deckle pantograph mill.

These machines were what shops used to do CNC before the ‘computer numeric’ part was a thing. By tracing out a template (which [Attoparsec] 3D prints, so he’s obviously no Luddite) complex shapes can be milled with ease. Complex shapes like a labyrnthine wafflemaker. Check out the full video below; it’s full of all sorts of interesting details about the machining process and the tools involved.

If you don’t need to machine cast iron, but are interested in the techniques seen here, a wooden pantorouter might be more your speed than a one-tonne antique. If you have a hankering for waffles but would rather use CNC, check out these design tips to help you get started. If pancakes are more your style, why not print them?

Shoutout to [the gambler] for sending this into the tip line. We think he struck the jackpot on this one. If you have a tip, don’t be shy. Continue reading “Antique Mill Satisfies Food Cravings”