Hall Effect Limit Switches For A 3D Printer

April 3, 2013 by Mike Szczys 39 Comments

hall-effect-limit-switches

We’re used to thinking of limit switches as a mechanical device that cuts the motor connection before physical damage can occur. [Anthony] decided to try a different route with this project. He built this set of no-contact limit switches using a hall effect sensor. The small black package sticking out past the end of the protoboard is the sensor. It is used to detect a magnetic field.

[Anthony] chose to use an Allegro A3144 sensor. Apparently it is no longer in production but was easy to find for a song and dance on eBay. When thinking about the design he decided to add two LED indicators, one lights when the switch is open and the other when it has been tripped. This would have been easy to do with just one LED, but he needed to add more parts to get both working. In the lower left corner of the protoboard you can see the configurable gate device (74LVC1G58) he added to monitor the hall effect sensor and switch the output and LEDs accordingly.

Installing GLaDOS In The Ceiling Of Your House

March 25, 2013 by Mike Szczys 14 Comments

glados-ceiling-light

Install this light fixture in your bedroom and you might kiss your nights of peaceful sleep goodbye. Fans of the Portal game franchise will recognize it as a smaller version of the megalomaniacal artificial intelligence character from the game. This particular rendition is how she looked in the second installment of the series. The lamp is the creation of [Dragonator]. It was entirely 3D printed before being outfitted with LEDs to actually function as a light.

Our first thought is that this project is all about 3D design to get the final product t0 look so fantastic. But if you dig a little deeper you’ll see that it’s so much more than that. To get pieces that look this fantastic you must have a well tuned printer and be willing to let it run for 40-60 hours as it burns through 2 kg of filament. At that point you’re still far from the finish line as the [Dragonator] then set to work sanding and painting all of the pieces. From there he lovingly assembled everything, including gears and motors to give it motion.

In the end the electronics did not work as he envisioned. But maybe after a bit of time off from all that work he’ll revisit the project and make a bit more progress. For us, the aesthetic already makes the hack. Making it move and sound like the character would be over the top.

If you liked this you can’t miss the GLaDOS potato.

Fixing Tools With 3D Printers

March 24, 2013 by Brian Benchoff No comments

saw

Over at the Manchester Hackerspace, [Bob] has been busy getting a 30-year-old bandsaw up and running. The saw worked great, but it was missing a fence, making straight cuts difficult to say the least. The solution, of course, was to build a new fence, and [Bob] decided to capitalize on his hackerspace’s workshop by making a new fence with a 3d printer.

[Bob] began by taking careful measurements of the saw’s table and the channel running down the length of it. These measurements were plugged into OpenSCAD, and after a few iterations, [Bob] had an extremely well-fitting profile a fence could be attached to.

With the profile down, [Bob] created a new part in OpenSCAD that would hold an aluminum angle piece. This was attached to the plastic parts with screws, and the entire assembly clamps down to the saw with the help of a few 5mm bolts. For a machine that is usually dedicated to making 3D printer parts and Yoda heads, [Bob] did a great job making good use of his 3D printer.

Smoothing 3D Prints With Acetone Vapor

March 23, 2013 by Eric Evenchick 9 Comments

If you’ve ever used an extruding 3D printer, you know that the resulting prints aren’t exactly smooth. At the Southackton hackerspace [James] and [Bracken] worked out a method of smoothing the parts out using vapor. The method involves heating acetone until it forms a vapor, then exposing ABS parts to the vapor. The method only works with ABS, but creates some good looking results.

Acetone is rather flammable, so the guys started out with some safety testing. This involved getting a good air to fuel mixture of acetone, and testing what the worst case scenario would be if it were to ignite. The tests showed that the amount of acetone they used would be rather safe, even if it caught fire, which was a concern several people mentioned last time we saw the method.

After the break, [James] and [Bracken] give a detailed explanation of the process.

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LulzBot Is Giving Away More Printers

March 22, 2013 by Brian Benchoff 1 Comment

LulzBot, the awesomely named 3D printer manufacturer and parts supplier, is giving away eight of their AO-100 printers to eight lucky hackerspaces.

It’s not so much a contest, but instead a giveaway aimed at eight community-operated hackerspaces who come up with a great idea on how to use a 3D printer. If you’re part of a well-established hackerspace that doesn’t have a 3D printer yet, this is a great opportunity to get your hands on a very nice printer.

A while back, we acquired one of these LulzBot printers to print off some custom gaming controllers for gamers with physical disabilities (and to make some other cool stuff as well). Our boss man [Caleb] says the AO-100 is a great printer, and in my dealings and purchases with LulzBot, they seem like a great company with great support. We’re sure the hackerspaces that win these printers LulzBot is giving away will be able to put them to use quickly by making some really cool stuff.

Printed Vacuum Pump Muffler Quiets The Lab

March 21, 2013 by Mike Szczys 46 Comments

printed-vacuum-pump-muffler

[Joel] made a brilliant improvement to his shop. If you think about it, most folks would hear a loud vacuum pump and either tolerate it or put in some ear plugs. But [Joel] heard a loud vacuum pump and thought: hey, I can fix that! His solution was to design and print his own muffler.

He did a bit of research on the topic and found that design complexity runs the gamut based on the application. For instance, you don’t want to affect the airflow of a vehicle’s exhaust too much or you will take a horsepower (and efficiency) hit for it. In this case the vacuum pump making all the noise has a relatively low airflow so that is not a concern. What he ended up doing is designing a baffle that will help cushion the vibrations in the airy by piping it through a maze of channels. The end result drops from about 92 dB to 82 dB. That might not seem like much, but decibel measurements aren’t linear so it ends up having a great effect. Hear for yourself in the video after the break.

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Midwest RepRap Festival

March 16, 2013 by Brian Benchoff 19 Comments

We’re a US-centric site, but aside from events in New York or California, we don’t see many hacker, maker, or 3D printer events aimed at the parts of the country filled with corn and WalMarts. The 1st annual Midwest RepRap Festival aims to change that with enough events, speakers, and activities to make Elkhart, Indiana look like the hoppingist place around.

Officially, the festival started yesterday but the schedule of events really ramps up today. [Josef Prusa] will be taking the stage talking about the state of the RepRap, and a ton of 3d printing vendors will be there showing off their wares and selling some really cool stuff. There’s also tons of experienced RepRappers available to help you tune your machine to perfection; just as well, because the festival is going for the world record for the greatest number of 3D printers printing simultaneously.

If you’re around northern Indiana, you might want to check out the festival and send us a few pics or videos.