A High Torque Gearbox You Can Print At Home

August 13, 2020 by Lewin Day 10 Comments

Typically, when we think of 3D printed parts, we think of unique parts with complex geometries that would be hard to fabricate with other techniques. Strength is rarely the first thing that comes to mind, due to the limitations of thermoplastics and the problem of delamination between layers. However, with smart design, it’s possible to print parts capable of great feats, just as [Brian]’s high-torque gearbox demonstrates.

Pulling a car is a great way to show off the strength of your build.

The gearbox consists of entirely 3D-printed gears, along with the enclosure, with the only metal parts being a few bearings and shafts. Capable of being produced out of PLA on a regular FDM printer, [Brian] has successfully tested the gearbox up to 132 kg∗cm. The suspicion is that there may be more left in it, but some slippage was noticed in the gear train when trying to tow a Ford Focus with the handbrake still on.

Even better, with the addition of a potentiometer, the gearbox can be used as an incredibly tough servo. [Brian] demonstrates this by lifting 22 kg at a distance of 6 cm from the center of the output shaft. The servo does it with ease, though eventually falls off the bench due to not being held down properly.

It’s a build that shows it’s possible to use 3D-printed parts to do some decently heavy work in the real world, as long as you design appropriately. [Brian] does a great job of explaining what’s involved, discussing gear profile selection and other design choices that affect the final performance. We’ve seen similar work from others before, too. Video after the break.

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3D Printing Interactive Maps For The Visually Impaired

August 11, 2020 by Lewin Day 3 Comments

Most maps and educational materials for teaching geography are highly visual in nature. For those with a visual impairment, it can make learning more difficult when suitable resources are not available. After visiting a boarding school in Moscow, [Sergei] set out to build an interactive map to teach students geography regardless of their vision status.

After seeing the poorly embossed paper maps used in the school, [Sergei] decided there had to be a better way. The solution was 3D printing, which makes producing a map with physical contours easy. Initial attempts involved printing street maps and world maps with raised features, such that students could feel the lines rather than seeing them.

Taking things a step further, [Sergei] went all out, producing an interactive educational device. The build consists of a world map, and contains audio files with information about countries, cultures, and more. When the ultrasonic sensor detects a user in range, it invites them to press or pull out the removable continents on the map. The device can sense touch, thanks to a pair of MPR121 capacitive touch sensor boards which are used to trigger the audio files.

It’s a great way to use the sense of touch to teach where the sense of vision may be lacking. Previous Prize entries have worked in this field too, like this haptic glove to help vision-impaired users interpret camera data. We can’t wait to see what comes next as technology improves!

Folding Raspberry Pi Enclosure Prints In One Piece, No Screws In Sight

August 11, 2020 by Donald Papp 14 Comments

[jcprintnplay] has challenged himself to making Raspberry Pi cases in different ways, and his Fold-a-Pi enclosure tries for a “less is more” approach while also leveraging the strong points of 3D printing. The enclosure prints as a single piece in about 3 hours, and requires no additional hardware whatsoever.

The design requires no screws or other fasteners, and provides a mounting hole for a fan as well as some holes for mounting the enclosure itself to something. All the ports and headers are accessible, and the folding one-piece design is not just a gimmick; in a workshop situation where the Pi needs to be switched out or handled a lot, it takes no time at all to pop the Raspberry Pi in and out of the enclosure.

Microsoft’s 3D Builder has a pretty useful measurement tool for STLs.

[James] points out that the trick with a print-in-place hinge like this is leaving enough space between the parts so that the two pieces aren’t fused together, but not so much space that the print fails. He doesn’t go into detail about how much space worked or didn’t work, but an examination of the downloadable model shows that the clearance used looks like 0.30 mm, intended to be printed with a 0.4 mm nozzle.

[James] also demonstrates the value of being able to do quick iterations on a design when prototyping. In a video (embedded below) The first prototype had the hinge not quite right. In the second prototype there was a lack of clearance when closing. The third one solved both and shows the final design.

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3D Printable Kinematic Couplings, Ready To Use

August 11, 2020 by Donald Papp 11 Comments

Time may bring change, but kinematic couplings don’t. This handy kinematic couplings resource by [nickw] was for a design contest a few years ago, but what’s great is that it includes ready-to-use models intended for 3D printing, complete with a bill of materials (and McMaster-Carr part numbers) for hardware. The short document is well written and illustrated with assembly diagrams and concise, practical theory. The accompanying 3D models are ready to be copied and pasted anywhere one might find them useful.

What are kinematic couplings? They are a way to ensure that two parts physically connect, detach, and re-connect in a precise and repeatable way. The download has ready-to-use designs for both a Kelvin and Maxwell system kinematic coupling, and a more advanced design for an optomechanical mount like one would find in a laser system.

The download from Pinshape requires a free account, but the models and document are licensed under CC – Attribution and ready to use in designs (so long as the attribution part of the license is satisfied, of course.) Embedded below is a short video demonstrating the coupling using the Maxwell system. The Kelvin system is similar.

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How Many Of You Are There, Really?

August 1, 2020 by Orlando Hoilett 40 Comments

We’re now accustomed to hearing, “We’re all special in our own unique ways.” But what if we weren’t really aren’t all that unique? Many people think there are no more than two political opinions, maybe a handful of religious beliefs, and certainly no more than one way to characterize a hack. But despite this controversy in other aspects as life, at least we can all rely on the uniqueness of our individual names. Or can you?

You ever thought there were too many people named [insert name here]? Well, [Nicole] thought there were too many people who shared her name in her home country of Belgium and decided to make an art piece out of it.

She was able to find data on the first names of people in Belgium and wrote a Python script…er…used Excel to find the number of Nicoles in each zip code. She then created a 3D map of Belgium divided into each province with the height of each province proportional to the number of Nicoles in that area. A pretty simple print job that any standard 3D printer can probably do these days.

Not much of a “do something” hack, but could make for a cool demotivational ornament that will constantly remind us just how unique we really are.

Happy hacking!

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Electric Skateboard With Tank Tracks, From A Big 3D Printer

July 31, 2020 by Danie Conradie 4 Comments

One of the basic truths of ground vehicles is that they are always cooler with tank tracks. Maybe not better, but definitely cooler. [Ivan Miranda] takes this to heart, and is arguably the king of 3D printed tank projects on YouTube. He has built a giant 3D printed electric skateboard with tank tracks with the latest version of his giant 3D printer. Videos after the break.

The skateboard consists of a large steel frame, with tracked bogies on either end. Most of the bogie components are 3D printed, including the wheels and tracks, and each bogie is driven by a brushless motor via a belt. Some bends were added to the steel frame with just 3D printed inserts for his bench vice. The bogies are mounted to the frame with a standard skateboard truck, which allows it to steer like a normal skateboard, by tilting the deck. It looks as though this works well on a smooth concrete floor, but we suspect that turning will be harder on rough surface where the tracks can’t slide. We’ll have to wait for the next video for a full field test.

The large components for this skateboard were printed on [Ivan]’s MK3 version of his giant 3D printer. Although it’s very similar to the previous version, improvements were made in key areas. The sliding bed frame’s weight was reduced by almost 50%, and the wheels were rotated, so they ride on top of the extrusion below it, instead of on it’s side, which helps the longevity of the wheels. This also allows bed levelling to be done by turning the eccentric spacers on each of the wheels. The rigidity of base frame and x-axis beam were increased by adding more aluminium extrusions. Although he doesn’t explicitly mention the print volume, it looks to be the same as the previous version, which was 800x500x500. For materials other than PLA, we suspect a heated build chamber will be required have any chance of making big prints without excessive warping.

[Ivan] really likes big prints, with a number of 3D printed tanks, a giant nerf gun, and a sand drawing bot. Continue reading “Electric Skateboard With Tank Tracks, From A Big 3D Printer” →

Producing A Prop Gun That Actually Ejects Cases

July 31, 2020 by Lewin Day 34 Comments

With the movie Man of War shooting in Cyprus, there was a problem. They needed prop guns that looked realistic and ejected cases when fired, but that were also allowed under the country’s firearm laws. The task fell on [Paradym’s] shoulders, and he set to work producing a prop capable of doing the job.

With the laws in Cyprus, using anything off-the-shelf like an Airsoft pistol was simply not allowed. Instead, he had to start from scratch, creating a design outwardly similar to the Colt 1911 to suit the era of the film. Using green gas canisters for power, the first focus was on getting a realistic semi-automatic firing cycle happening. With that done, the next goal was to get the cases to eject from the weapon on each shot. To achieve this, a lever was used, actuated by the slide moving back after a shot, pushing the “spent” cartridge out of the port.

[Paradym] goes into great deal, covering the design of the 3D printed parts, the machining of springs, as well as the final assembly of the prop. We’ve seen other prop gun builds before, too. Video after the break.

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