3d Printer hacks

2559 Articles

Simple Sensor Makes Filament Measurements A Snap

February 7, 2021 by 29 Comments

Just how tight are the manufacturing tolerances of modern FDM printer filament. Inquiring minds want to know, and when such minds are attached to handy fellows like [Thomas Sanladerer], you end up with something like this home-brew filament measurement rig to gather the data you seek.

The heart of this build is not, as one might assume, some exotic laser device to measure the diameter of filament optically. Those exist, but they are expensive bits of kit that are best left to the manufacturers, who use them on their production lines to make sure filament meets their specs. Rather, [Thomas] used a very clever homemade device, which relies on a Hall effect sensor and a magnet on a lever to do the job. The lever is attached to a roller bearing that rides on the filament as it spools through the sensor; variations in diameter are amplified by the lever arm, which wiggles a magnet over the Hall sensor, resulting in a signal proportional to filament diameter.

The full test rig has a motor-driven feed and takeup spools, and three sensors measuring across the filament in three different spots around the radius; the measurements are averaged together to account for any small-scale irregularities. [Thomas] ran several different spools representing different manufacturers and materials through the machine; we won’t spoil the results in the video below, but suffice it to say you probably have little to worry about if you buy from a reputable vendor.

When we see a filament sensor, it’s generally more of the “there/not there” variety to prevent a printer from blindly carrying on once the reel is spent. We’ve seen a few of those before, but this is a neat twist on that concept.

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Hands On With The Voltera V-One PCB Printer

February 5, 2021 by 42 Comments

Creating your own PC board is a rite of passage for many. These days, though, you can order super inexpensive boards and have them in very little time, so it doesn’t always make sense to build your own. Still, some people like the challenge, and others don’t want to wait even a few days. Probably everyone has dreamed of a 3D printer-like machine that would just crank out beautiful PCBs. The Voltera V-One isn’t quite at that level of sophistication, but it isn’t too far from it. [Great Scott] shows us how he built two different boards using the system in the video below. While the results were impressive, you can also see that there are several limitations, especially if you are not designing your board with the machine in mind.

One thing that is obvious is that the machine does need your help. In addition to aligning holes, you’ll need to install tiny rivets for vias and slightly less tiny rivets for through-hole components. The last time we looked at the machine, it didn’t do holes at all, but [Scott] shows the drill attachment which allows the machine to produce vias and support leaded components.

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Simple 3D Printed Seven-Segment Displays

February 2, 2021 by 7 Comments

7-segment LED displays were revolutionary, finally providing a clear, readable and low-power numerical display solution. We’ve got plenty of other cheap display options now, but sometimes you just need the old nought-through-nine, and in a big, visible package, to boot. For those circumstances, consider whipping up a set of these 3D-printed seven-segment displays.

The build consists of a 3D printed frame, with each segment containing two WS2812B addressable LEDs. Each 7-segment assembly is then wired so they can be daisy chained, passing on data to the next digit in the chain. Paper is used to diffuse the LEDs for a smoother look, and a white 3D printed cover is printed for each digit to further spread the light and give a clean finish.

Being based on the WS2812Bs, it’s easy to drive such displays with just about any microcontroller or GPIO-equipped Linux board out there. We love big, beautiful displays – and the more artistic, the better. Video after the break.

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Art of 3D printer in the middle of printing a Hackaday Jolly Wrencher logo

3D Printering: Why Aren’t Enclosures Easier?

February 2, 2021 by 101 Comments

For 3D printers that aren’t already enclosed, why is easily adding a cheap and effective enclosure still not a completely solved problem? The reason is simple: unless one’s needs are very basic, enclosures are more than just boxes.

Different people need different features, printers come in different shapes and sizes, and creating something that can be both manufactured and shipped cheaply is a challenge in itself. In this article I’ll explain how those things make boxing up your printer a tougher nut to crack then may seem at first glance.

Enclosures Have Different Jobs

People have different expectations of what an enclosure’s job should be, and that determines which features are important to them and which are not. Here is a list of meaningful features for 3D printer enclosures; not everything on this list is important to everyone, but everything on this list is important to someone. Continue reading “3D Printering: Why Aren’t Enclosures Easier?” →

3D Printing An Ion Propulsion System

January 27, 2021 by 20 Comments

As much as we love Star Trek, we have to admit there are some continuity problems. For example, in Spock’s Brain, the alien-of-the-week’s ion drive gave Scotty engineering envy. However, in The Menagerie, the computer identifies a Starfleet shuttlecraft as having ion propulsion. Either way, ion propulsion is real and NASA has toyed with it for ages and many satellites use it for maintaining orbit. Now researchers from MIT and the Monterrey Institute of Technology and Higher Studies 3D printed tiny ion engines.

The engine is about the size of a dime and, like all ion engines, produces tiny amounts of thrust. In fact, the researchers liken it to half the weight of one sesame seed from a hamburger bun. However, in space, these tiny thrusts add up and over time can produce significant acceleration.

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3D Printed Box Gets Bigger

January 26, 2021 by 10 Comments

If you ever watched Dr. Who, you probably know that the TARDIS looked like a police call box on the outside, but was very large on the inside. When asked, the Doctor had some explanation of how something can look small when it is far away and large when it is close up, which never made much sense. However, [iQLess] has been 3D printing boxes in a small area, that fold out to be much larger boxes. (Video, embedded below.) The design comes from someone called [Cisco] who has a lot of interesting print in place designs.

You can find the design on the Prusa site or Thingiverse. The boxes do take a while to print, according to the video below. What was interesting to us, though, is that you should be able to print a design like this to create a box larger than your printer.

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OpenSCAD Prints Woodworking Aid

January 23, 2021 by 24 Comments

Home-based 3D printing is getting pretty unremarkable. Sure, printers aren’t as ubiquitous as, say, PCs. But you wouldn’t be any more surprised if your neighbor had a 3D printer than if you found out they had a drill press. In fact, sometimes the real value of 3D printing something isn’t to make a working part, but to make up something that helps you create other things using methods other than printing. That’s exactly what [iqless] does when he uses his printer to make some jigs to help him easily build shelves. (Video, embedded below.)

The issue is making dowel joints for the shelve’s feet. Sure, you could just drill a piece of scrap wood as a template, but with a 3D printer you can do better. Using OpenSCAD, it is possible to create a parameterized jig that fits exactly the job at hand.

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