When Does Moving To Resin 3D Printing Make Sense?

October 2, 2019 by Donald Papp 50 Comments

An Elegoo Mars resin 3D printer, straight to my doorstep for a few hundred bucks. What a time to be alive.

Resin-based 3D printers using digital light processing (DLP) and especially stereolithography (SLA) are getting more common and much more affordable. Prosumer-level options like Formlabs and the Prusa SL1 exist, but more economical printers like the Elegoo Mars, Anycubic Photon, and more can be had for a few hundred bucks. Many printers and resin types can even be ordered directly from Amazon, right at this moment.

Resin prints can look fantastic, so when does it make sense to move to one of these cheap resin printers? To know that, consider the following things:

The printing process and output of resin printers is not the same as for filament-based printers. Design considerations, pre-processing, and post-processing are very different.
Resin printing has a different workflow, with consumables and hidden costs beyond the price of resin refills.

Things may not be quite where fused deposition modeling (FDM) printers were just a few short years ago when we were extremely impressed with the quality of printer one could get for about $200, but it is undoubtedly far more accessible than ever before. Let’s look at how to inform a decision about whether to take the plunge. Continue reading “When Does Moving To Resin 3D Printing Make Sense?” →

Copper Coil Lamp Built With 3D Printed Tools

October 1, 2019 by Lewin Day 7 Comments

3D printing is a great way to create complex geometric forms. However, it can be very slow, and parts may lack strength compared to other alternatives. There are other ways to take advantage of this technology however, as shown in the build of this tidy voronoi lamp.

The lamp is so-called for its voronoi-patterned base, named after the mathematical concept. 3D printing is used to create the base, which would be very difficult to create with traditional subtractive machining methods. A copper coil is then used to give the lamp some height, as well as act as protection for the filament bulb. Here, 3D printing helps out in a different way, being used to create a jig to allow the copper to be quickly wound into an accurate coil shape. The coil also serves to act as a conduit for the mains wiring, giving the lamp a neat finished appearance.

The project goes to show that even if 3D printing is appropriate to produce your final parts, it may be of help to create useful jigs or tools to get the job done. We’ve even seen similar applications before in the microcontroller space!

3D Print Your Own Thermal Insert Press

October 1, 2019 by Lewin Day 23 Comments

Thermal inserts are a big thing when it comes to engineering with plastic. They make it easy to use threaded fasteners with plastic parts, and they work great with 3D printing too. There’s a bit of a knack to installing them without damaging your workpiece, however, and [John Culbertson] wanted to make using them as easy as possible. Thus, he created a thermal insert press of his very own!

If you’re not using heat-set inserts with your 3D printed parts you’re missing out. Hackaday’s own [Joshua Vasquez] wrote a great guide on thermal inserts which you heat up to securely melt the plastic as they are pushed into a slightly under-sized hole. While it’s possible to install these inserts by hand, using a press means much more consistent results.

This press relies on 3D printed components in combination with off-the-shelf bearings and fasteners. There’s a linear rail as well, to give the soldering iron a clean, smooth downward motion. This helps make sure that the inserts go in straight and true, first time, every time. We’ve seen other DIY builds before, like this modified arbor press that gets the job done. Continue reading “3D Print Your Own Thermal Insert Press” →

3D Printing Is Transformative Experience For Airgun Shooter

September 28, 2019 by Donald Papp 5 Comments

It’s interesting to peek into other scenes and niches and see how they intersect with things that one may find commonplace, like 3D printing. In this case, [NewToOldGuns] wrote a guest blog post for PyramydAir (a retailer, so be prepared for a lot of product links) about how 3D printing has completely transformed the experience of how he uses one of his favorite airguns, and allowed him to make changes and improvements that would not otherwise have been practical.

Not only are the 3D printed improvements thoughtful and useful, but it’s interesting to see familiar insights into the whole design process. After explaining some 3D printing basics, he points out that rapid iteration is key to effective prototyping, and a 3D printer can allow that to happen in a way not previously possible.

The pellets held inside the silver cylinder can no longer fall out, and the orange holder allows it to be simply pushed straight through into the gun’s receiver.

It all started with the small magazine which holds the rifle’s projectiles. It would be really handy to pre-load these for easier reloading, but there were practical problems preventing this. For one thing, there’s nothing to really hold the pellets in place and keep them from just falling out when it’s not loaded into the gun. Also, loading them into the gun without letting anything fall out was awkward at best. The solution was to design a simple holder that would cradle the magazine and cover the front and back to keep everything in place. [NewToOldGuns] also designed it so that it could mate directly to the gun, so the magazine could simply be pushed straight into the receiver while the action was held open.

Once this simple part was working, the floodgates of creativity were opened. Next was a belt attachment to hold multiple reloads, followed by a decision to mount the reloads directly onto the gun instead. An improved lever and sights quickly followed.

I also demonstrated the iterative approach to prototyping when I designed a simple alarm to detect when my 3D printer’s filament had run out. [NewToOldGuns] observes that the real power of 3D printing isn’t being able to make bottle openers or coat hooks on demand. It’s the ability to imagine a solution, then have that solution in hand in record time.

Silicone Injector Gives Parts Production A Shot In The Arm

September 26, 2019 by Kristina Panos 14 Comments

Many of us are happy to spend hours cooking up a solution that saves us seconds, if success means never having to do a hated task again. [frankensteinhadason] molds enough silicone parts that he grew tired of all the manual labor involved, so he built a silicone injector to do it for him. Now, all he has to do is push the handle in notch by notch, until silicone starts oozing from the vent holes in the mold.

The mold pictured above is designed to make little shrouds for helicopter communications connections like this one. His friends in the industry like them so much that he decided to sell them, and needed to scale up production as a result. Now he can make six at once.

He designed brackets to hold a pair of syringes side by side against a backplane. There’s a lever that pushes both plungers simultaneously, and adapters that keep the tubing secured to the syringe nozzles. Ejected two-part silicone travels down to a double-barrel mixing nozzle, which extrudes silicone into the top of the mold.

Naturally, we were going to suggest automating the lever operation, but [frankensteinhadason] is already scheming to do that with steppers and an Arduino. Right now he’s working on increasing the hose diameter for faster flow, which will mean changes to the adapter. Once that is sorted, he plans to post the STLs and a video of it pumping silicone.

Ever thought about doing the reverse, and using silicone to mold hot plastic? Yeah, that’s a thing.

Via r/functionalprint

Magnets Make This Panda Move

September 23, 2019 by Kerry Scharfglass 17 Comments

A single board computer on a desk is fine for quick demos but for taking it into the wild (or even the rest of the house) you’re going to want a little more safety from debris, ESD, and drops. As SBCs get more useful this becomes an increasingly relevant problem to solve, plus a slick enclosure can be the difference between a nice benchtop hack and something that looks ready to sell as a product. [Chris] (as ProjectSBC) has been working on a series of adaptable cases called the MagClick Case System for the LattePanda Alpha SBC which are definitely worth a look.

The LattePanda Alpha isn’t a run-of-the-mill SBC; it’s essentially the mainboard from a low power ultrabook and contains up to an Intel Core M series processor, 8GB RAM, and 64GB of eMMC. Not to mention an onboard Atmega32u4, WiFi, Gigabit Ethernet, and more. It has more than enough horsepower to be used as an everyday desktop computer or even a light gaming system if you break PCIe out of one the m.2 card slots. But [Chris] realized that such adaptability was becoming a pain as he had to move it from case-to-case as his use needs changed. Thus the MagClick Case System was born.

Continue reading “Magnets Make This Panda Move” →

Can You Read Me The Time?

September 21, 2019 by Sharon Lin 11 Comments

If you’re like the average clock user, you’ve probably gotten annoyed at reading analog clocks before. Typically, the solution is just to use a digital timepiece, but [sjm4306] has opted to make a small word clock that you can carry with you wherever you go to remind you of the time in the English language.

Unlike a similar project made by [Gordan Williams], which uses an 8 x 8 LED matrix with an inkjet printed overlay, this small word clock uses a 3D-printed light box to achieve its letter matrix. In fact, they were inspired by all of the existing DIY word clock designs using anything from off-the-shelf LED arrays, transparency masks and WS2812s.

The design uses a home-brewed PCB design that runs off 5 V via USB. The design places the letters on the top stop and restricts layers to keep the solder mask and copper from obstructing the light. The bottom side uses the same design principle with a square shape that overlaps the letter. In order to block light between adjacent letters, the 3D-printed light box comes into play.

One design challenge for the letter matrix was fitting all possible minutes into the array. Rather than making a larger array of letters, [sjm4306] had the clock describe the time down to five-minute intervals then add asterisks for the full time. It’s a pretty understandable solution for keeping the design simple, and the letters all fit onto the design so well!

Using a pin map assigned to the I/O for the rows and columns of the array, the software toggles the states of the pins as a switch statement. For scanning the matrix, the software uses an interrupt that draws the current column of LEDs and updates the display image before incrementing to the next column. By skipping or not skipping cycles, this allows the display to look brighter or dimmer.

The time tracking is fairly simple, using a DS1302 serial real time clock chip – it even charges a super capacitor to keep time after power is removed!

To tackle the light scattered internally in the PCB’s FR4 material, a separator is used to contain the light. As a low-cost solution, while there is still some amount of light diffused, it’s definitely better than without the separator.

Almost all of the files used for building the small word clock are available on [sjm4306]’s project page, including the software and design files. It hopefully won’t be too long before we start seeing more of these low-cost word clock designs!

Continue reading “Can You Read Me The Time?” →