Learn The Secrets Of Matching Bottle Cap Threads To One Another

July 12, 2020 by Donald Papp 24 Comments

Do you want to design something to match existing threads on a bottle, or a cap? It turns out there’s an easier way than reaching tiredly for the calipers and channeling one’s inner reverse-engineer. Bottle cap threads — whose industry term is the neck finish — aren’t arbitrary things; they are highly standardized, and [Noupoi] researched it all so that you don’t have to! The Bottle Cap Thread Calculator takes a few key measurements and spits out everything needed to model exact matches. Need some guidance on how exactly to use the information the calculator spits out? There is a handy link to a Fusion360 tutorial on creating bottle threads (YouTube video) to demonstrate.

This all came from [Noupoi] wanting to model an adapter to transfer the contents of one bottle to another, smaller bottle. By identifying which thread was used on each bottle, the job of modeling a matching adapter was much easier. It turns out that the bottle necks were an SP 28-415 (larger) and a 24-415 (smaller), and with that information the adapter was far simpler to design. If you want to check the adapter out, it’s available on Thingiverse.

If truly reverse-engineering bottle threads is needed, here’s a method we covered that involves making a simple cast and working from that.

[via Reddit]

3D Printering: Selling Prints, And Solving The Pickup Problem

July 8, 2020 by Donald Papp 23 Comments

After getting a 3D printer up and running, it’s not uncommon for an enterprising hacker to dabble in 3D printing to make a little money on the side. Offering local pickup of orders is a common startup choice since it’s simple and avoids shipping entirely. It’s virtually tailor-made to make a great bootstrapping experiment, but anyone who tries it sooner or later bumps up against a critical but simple-seeming problem: how to get finished prints into a customer’s hands in a sustainable way that is not a hassle for either the provider, or the customer?

It’s very easy to accept a 3D file and get paid online, but the part about actually getting the print into the customer’s hands does not have a one-size-fits-all solution. This is what I call The Pickup Problem, and left unsolved, it can become unsustainable. Let’s look at why local pickup doesn’t always measure up, then examine possible solutions.

The Problems with Local Pickup

Local pickup for delivery of print jobs is great because there is no mucking about with shipping supplies or carriers. Also, many 3D prints when starting out will be relatively low-value jobs that no one is interested in stacking shipping fees onto, anyway.

“Your order is complete. Come to this address to pick up your order.” It is straightforward and hits all the bases, so what’s the problem?

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New (mis)Use For Lithophanes: Miniature Diorama Backgrounds

July 6, 2020 by Donald Papp 3 Comments

What’s better than a well-lit photo of a 3D-printed miniature? A photo of the miniature in a mini diorama, of course. [OrionDeHunter] shows off a clever technique that has something in common with old-timey photo stages and painted backgrounds, and (mis)uses 3D-printed lithophanes to pull it off. What [OrionDeHunter] does is use a curved and painted lithophane as a stand-in for a background, and the results look great!

Lithophanes are intended to be illuminated from behind to show an image, with thin areas showing as lighter and thicker areas darker, but when it comes to high contrast patterned images like brick walls, the same things that make a good lithophane just happen to also make a pretty good 3D model in the normal sense. No 3D scanning or photogrammetry required.

Here is the basic process: instead of creating a 3D model of a brick wall from scratch, [OrionDeHunter] simply converted an image of a brick wall (or stairs) into a curved lithophane with an online tool. The STL model of the lithophane is then 3D printed, painted, and used as a swappable background. When macro shots of the miniatures are taken, the curved background looks just right and allows for some controlled lighting. It’s a neat trick, and well applied in this project. Some sample images demonstrating how it works are just under the break.

A painted lithophane makes a convincing brick wall

Other images like these stairs can work, too.

Lithophanes were originally made using marble or thin porcelain, but a modern spin has been put on the technique with 3D printing. Enterprising hackers have even discovered ways to add color, too.

3D-Printing Bigger Wind Turbines

July 6, 2020 by Dan Maloney 66 Comments

Many decades ago, a much younger version of me was in the car with my dad and my brother, cruising down the highway on some errand or another. We were probably all in the front seat, and none of us were wearing seatbelts; those were simpler times. As we passed under an overpass, my dad said, “Do you know why the overpasses on these roads are so high?” Six-year-old me certainly didn’t, but it was clear dad did and had something to say about it, so we just shook our heads and waited for the lesson. “Because that’s how big nuclear missiles are.” He then went into an explanation of how the Interstate Highway System in the USA, then still in its infancy, was designed to make sure the armed forces could move around the country, so overpasses needed to allow trucks with big loads to pass.

It was an interesting lesson at the time, and over the years I’ve continued to be impressed with the foresight and engineering that went into the Interstate system here in the US. It’s far from perfect, of course, and it’s only recently that the specifications for the system have started to put a pinch on things that seem totally unrelated to overpass dimensions — namely, the size and efficiency of wind turbines.

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Elegant Shoji Lamps From Your 3D Printer

July 6, 2020 by Tom Nardi 12 Comments

The gorgeous Shoji-style lamps you’re seeing here aren’t made of wood or paper. Beyond the LEDs illuminating them from within, the lamps are completely 3D printed. There aren’t any fasteners or glue holding them together either, as creator [Dheera Venkatraman] used authentic Japanese wood joinery techniques to make their components fit together like a puzzle.

While we’re usually more taken with the electronic components of the projects that get sent our way, we have to admit that in this case, the enclosure is really the star of the show. [Dheera] has included a versatile mounting point where you could put anything from a cheap LED candle to a few WS2812B modules, but otherwise leaves the integration of electronic components as an exercise for the reader.

All of the components were designed in OpenSCAD, which means it should be relatively easy to add your own designs to the list of included panel types. Despite the colorful details, you won’t need a multi-material printer to run them off either. Everything you see here was printed on a Prusa i3 MK3S in PETG. Filament swaps and careful design were used to achieve the multiple colors visible on some of the more intricate panels.

If the timeless style of these Japanese lanterns has caught your eye, you’ll love this beautiful sunrise clock we covered last year.

DIY Baby MIT Cheetah Robot

July 5, 2020 by Orlando Hoilett 7 Comments

3D printers have become a staple in most makerspaces these days, enabling hackers to rapidly produce simple mechanical prototypes without the need for a dedicated machine shop. We’ve seen many creative 3D designs here on Hackaday and [jegatheesan.soundarapandian’s] Baby MIT Cheetah Robot is no exception. You’ve undoubtedly seen MIT’s cheetah robot. Well, [jegatheesan’s] hack takes a personal spin on the cheetah robot and his results are pretty cool.

The body of the robot is 3D printed making it easy to customize the design and replace broken parts as you go. The legs are designed in a five-bar linkage with two servo motors controlling each of the four legs. An additional servo motor is used to rotate an HC-SR04, a popular ultrasonic distance sensor, used in the autonomous mode’s obstacle avoidance mechanism. The robot can also be controlled over Bluetooth using an app [jegatheesan] developed in MIT App Inventor.

Overall, the mechanics could use a bit of work — [jegatheesan’s] baby cheetah probably won’t outpace MIT’s robot any time soon — but it’s a cool hack and we’re looking forward to a version 3. Maybe the cheetah would make a cool companion bot?

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IWings For The New Apple Power Adaptor

July 3, 2020 by Adil Malik 13 Comments

You might remember the old Apple MagSafe adaptor with the cute little fold out “wings” that served not only as a pragmatic cable management tool, but in our experience also expedited the inevitable and frayed end of your charger. Apple seems to have remedied the latter by opting for removable USB-C cables in latest designs, but the complete omission of a pop-out cable spooling contraption is problematic.

[Eric], an industrial designer, took it upon himself to design a 3D printed add on for the new generation of chargers. His video is certainty one of those satisfying accounts, where the whole process from conceptional sketch to a working Hack is neatly self-contained in a single video. The design is largely based off the original version, implemented in PLA together with piano wire serving as the hinge pin. We think this is a very good example of how 3D printers can be used to personalise and tweak commercial products to suite particular needs.

If you are looking for a more general 3D printed cable management tool, check out this geared cable winder we featured earlier.