3D Printed Doggie Braces

July 25, 2020 by Orlando Hoilett 2 Comments

[Tye’s] dog Lucifur unfortunately has degenerative arthritis causing her a lot of pain in her feet. The vet suggested orthotic carpal braces to help alleviate the pain, but they come at a price tag of at least $1600. Given her current budgetary limitations, [Tye] decided to try the DIY route.

The first task was to cast Lucifur’s paws in plaster to make a mold of her feet in both the weight-bearing and non-weight-bearing orientations. According to [Tye], the non-weight-bearing orientation is more representative of the shape of a “normal” paw, but she also needed to model the weight-bearing orientation to better design the braces for walking.

Then it was time to print a PLA-based dog splint from a design she found on Thingiverse. Since PLA softens when it’s in boiling water, the splint can be easily molded to Lucifur’s paw. This is where the paw molds [Tye] made earlier come in handy, since nobody would want Lucifur wearing a PLA splint fresh out of boiling water. Finally, she added a bit of super glue to the heel of the splint in hopes that it will hold up better over time.

We certainly can’t recommend DIY solutions to medical problems and [Tye] made sure she stressed the importance of following the recommendations of your vet if you’re ever in her position. Either way, we hope Lucifur finds some momentary reprieve, and that she can eventually receive those $1600 braces she desperately needs.

3D Printed Speaker Uses DSP For Ultimate Performance

July 25, 2020 by Lewin Day 17 Comments

Speaker design used to be as much about woodwork as it was about advanced acoustic mathematics. In recent decades, technologies such as digital signal processing and 3D printing have changed the game significantly. Leaning heavily on these techniques, [ssashton] developed a design called Mr. Speaker.

The speaker contains a 3″ woofer for good bass response, and twin tweeters to deliver stereo audio. Using WinISD to help do the requisite calculations on porting and volume, [ssashton] designed a swooping 3D printed enclosure with a striking design. Sound comes into the unit through an off-the-shelf Bluetooth module, before being passed to an ADAU1401 digital signal processing unit. From there, it’s passed to a mono amp to drive the woofer and a stereo one for the tweeters.

To get the flattest frequency response possible and maintain linear phase, it’s all about DSP in this case. RePhase software was used to design a DSP filter to achieve these goals, helping the speaker to produce the desired output. The ADAU1401 DSP was then programmed using Sigma Studio, which also allows the designer to do things such as split outputs for seperate woofer and tweeter drives.

[ssashton] does a great job of explaining both DSP principles and old-school speaker design tricks, from phase plugs to reflections. The use of 3D printed parts to rapidly iterate the design is impressive, too. We’d love to see the final enclsoure get an acetone smoothing treatment to really take it over the edge.

If you’re into serious speaker design and want more, be sure to check out this advanced transmission line design. For those of you with your own builds with some nifty tricks, drop us a note on the tipline.

Appeasing Chicken Tastes With 3D Printing

July 23, 2020 by Erin Pinheiro 4 Comments

Like most of us, [Hunter] and his partner [Katyrose] have been in quarantine for the past few months. Unlike most of us, they spun a 3D printed chicken playground design hackathon out of their self-isolation. The idea is simple: to build a playground full of toys custom-tailored to appease each chicken’s distinctive taste. The execution, however, can be proven a little tricky given that chickens are very unpredictable.

For each of the four select chickens in their coop, the couple designed separate toys based on their perceived interests. One, showing a fondness for worms, inspired the construction of a tree adorned with rice noodles in place of the living article, and moss to top it off. For late-night entertainment, the tree is printed in glow-in-the-dark filament. The others were presented with a print-in-place rotating mirror disguised as a flower, and a pecking post covered in peanut butter and corn. As a finishing piece, the fourth toy is designed as a jungle gym post with a reward of bread at the top for the chicken who dares climb it. Since none of the chickens seemed interested in it, they were eventually hand-fed the bread.

With no other entries to their hackathon, [Hunter] declared themselves as the winners. The 3D files for their designs are available for their patrons to print, should they have their own chicken coops they want to adorn. While the hackathon might’ve been a success for them, their chickens in particular seemed unimpressed with their new toys, only going to show that the only difference between science and messing around is writing it down, or in this case, filming the process. If you’re looking for other ways to integrate your chickens into the maker world, check out this Twitch-enabled chicken feeder, or this home automation IoT chicken coop door. Meanwhile, check out the video about their findings after the break.

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Robot, Sudo Fold My Laundry

July 22, 2020 by Al Williams 11 Comments

[Ty Palowski] doesn’t like folding his many shirts. He saw one of those boards on TV that supposedly simplifies folding, but it does require you to manually move the board. That just won’t do, so [Ty] motorized it to create a shirt folding robot.

The board idea is nothing new, and probably many people wouldn’t mind the simple operation required, but what else are you going to do with your 3D printer but make motor mounts for a shirt folding machine? The folding board is, of course, too big for 3D printing so he made that part out of cardboard at first and then what looks like foam board.

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Can A 3D Printer Print Better Filament For Itself?

July 20, 2020 by Adil Malik 21 Comments

3D printed parts are generally no way near the strength of an equivalent injection moulded part and techniques such as a sustained heat treatment, though effective usually distort the part beyond use.

[CNC Kitchen] was investigating the results (video, embedded below) of a recent paper, that described a novel ABS filament reinforced by a “star” shaped Polycarbonate core, an arrangement the authors claim is resilient to deformation during the annealing process often necessary to increase part strength. While the researchers had access to specialised equipment needed to manufacture such a composite material, [CNC Kitchen’s] solution of simply using his dual extruder setup to directly print the required hybrid filament is something we feel, strongly resonates with the now old school, RepRap “print your printer” sentiment.

The printed filament seems to have reasonable dimensional accuracy and passing the printed spool through a heater block without the nozzle attached, ensured there would be no obvious clogs. The rest of the video focuses on a very thorough comparison of strength and deformation between the garden variety Polycarbonate, ABS and this new hybrid filament after the annealing process. Although he concludes with mixed results, just being able to combine and print your own hybrid filament is super cool and a success in its own right!

Interested in multi-material filaments? Check out our article on a more conventional approach which does not involve printing it yourself!

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There’s An Engineer In Germany I’d Like A Word With; Tale Of A Crumbling Volkswagen Lock

July 20, 2020 by Jenny List 149 Comments

In common with quite a few in the hardware hacking community, I have a fondness for older vehicles. My “modern” ride is an older vehicle by today’s standards, a Volkswagen Polo 6N made in the late 1990s. It’s by my estimation a Good Car, having transported me reliably back and forth across the UK and Europe for several years.

Last week though, it let me down. Outside the church in a neighbouring village the driver’s door lock failed, leaving me with my igniton key stuck in the door, and a mildly embarrassing phone call to my dad to bring the Torx driver required to remove the assembly and release it. I am evidently not 1337 enough, I don’t carry a full set of Torx bits with me everywhere I go. The passenger side lock has never worked properly while I’ve had the car, and this is evidently my cue to sort it all out.

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Automated Part Removal Gets Serious With The Chain Production Add-on

July 20, 2020 by Donald Papp 46 Comments

Giving a 3D printer the ability to remove its own prints means that it can crank out part after part automatically, without relying on a human operator between jobs. [Damien Weber] has done exactly that to his Prusa MK3/S printer, with what he calls the Chain Production Add-on.

[Damien]’s approach is one we haven’t quite seen before. When printing is complete, a fan cools the part then an arm (with what looks like utility knife blades attached at an angle) swings up and behind the bed. The arm zips forward and scoops the print off the bed, dumping the finished part in the process. It’s all made from 3D printed parts, aluminum extrusion and hardware, two stepper motors, and a driver PCB. The GitHub repository linked above holds all the design files, but there is also a project page on PrusaPrinters.org.