Don’t Let Your PLA Filament Hang Loose With This 3D-Printed Surfboard

April 13, 2020 by Moritz v. Sivers 8 Comments

People always tend to push the boundaries of what is doable with a 3D printer. This is also true for [AndrewW1977] when he decided to 3D print a full-sized functional surfboard.

With just over nine full days of printing time, 95 individual pieces, and using 3.1 kg of PLA (not counting all the test prints), this is certainly a monumental project. One of the bigger issues [AndrewW1977] had to solve was avoiding air pockets inside the board. Ideally, you would want to end up with only one continuous hollow chamber in order to easily vent all the air inside the board when it heats up. [AndrewW1977] chose to overcome this problem by using zero infill for each individual piece. The pieces were then connected with the help of alignment pins that have a central hole thereby connecting all hollow chambers.

By using a triangular shape, he managed to print all pieces without using supports. After gluing them together the whole board was covered with fiberglass and epoxy resin similar to traditional surfboard building. Unfortunately, due to the current situation with Covid19 [AndrewW1977] remains short of showing us the board in action. In case you have a 3D printer at home and lots of spare time during lockdown, [AndrewW1977] has published all files for his surfboard on Thingiverse.

As [AndrewW1977] points out in the video embedded below other people have already done similar projects. From jet boats to electric hydrofoils it seems that water sports and 3D printing are a perfect match.

Continue reading “Don’t Let Your PLA Filament Hang Loose With This 3D-Printed Surfboard” →

Stitching Up Custom Belts

April 12, 2020 by Tom Nardi 17 Comments

If you’ve got a 3D printer, you’re probably familiar with the reinforced belts that are commonly used on the X and Y axis. These belts either come as long lengths that you attach to the machine on either end, or as a pre-sized loop. Traditional wisdom says you can’t just take a long length of belt and make your own custom loops out of it, but [Marcel Varallo] had his doubts about that.

This is a simple tip, but one that could get you out of a bind one day. Through experimentation, [Marcel] has found that you can use a length of so-called GT2 belt and make your own bespoke loop. The trick is, you need to attach the ends with something very strong that won’t hinder the normal operation of the belt. Anything hard or inflexible is right out the window, since the belt would bind up as soon as it had to go around a pulley.

It seems the key is to cut both ends of the belt very flat, making sure the belt pattern matches perfectly. Once they’ve been trimmed and aligned properly, you stitch them together with nylon thread. You want the stitches to be as tight as possible, and the more you do, the stronger the end result will be.

[Marcel] likes to follow this up with a bit of hot glue, being careful to make sure the hardened glue takes the shape of the belt’s teeth. The back side won’t be as important, but a thin layer is still best. The end result is a belt strong enough for most applications in just a few minutes.

Would we build a 3D printer using hand-stitched GT2 belts? Probably not. But during a global pandemic, when shipments of non-essential components are often being delayed, we could certainly see ourselves running some stitched together belts while we wait for the proper replacement to come in. Gotta keep those face shields printing.

Plasma Cutter + Sharpie Is Surprisingly Useful

April 10, 2020 by Al Williams 14 Comments

What we want is a Star Trek-style replicator. What we have are a bunch of different machines that can spew out various 2D and 3D shapes. For the foreseeable future, you’ll still need to post-process most of what you build in some way. [Stuff Made Here] had a challenge. He often uses his plasma cutter to create complex sheet metal items. But the cutter is two dimensional so the piece doesn’t look right until you bend it at just the right places. If you are doing a simple box, it is easy to figure out, but getting just the right spot on a complex bend can be a challenge. His answer? Attach a marker to the gantry so the machine can draw the lines right on the sheet metal.

Sounds easy and if you were willing to do a pen pass separately and then remove the pen and do the plasma cutting it would be relatively easy. However, that seems kind of crude. Mounting it permanently requires a way to raise it up when cutting — and it needs to survive the noisy environment near the torch. The pen would also dry out if you left in uncapped. The answer was using a permanent marker with a click retractor and let the mechanism extend and retract the pen point on command.

Continue reading “Plasma Cutter + Sharpie Is Surprisingly Useful” →

3D Printing Fishing Lure Molds

April 10, 2020 by Al Williams 7 Comments

Every fisherman has a secret. A secret spot, a secret technique, or a secret bait. Maybe that’s why tying flies is so popular. [Steve] certainly has is own special lures, although he’s not keeping it a secret. (Video, embedded below.) He designs lures in Simplify3D, 3D prints molds, and then casts them.

The 3D printing part is interesting, but it is also kind of neat to see the lures and the natural prey he uses for inspiration. If you want to catch fish, you have to use bait that looks like real food.

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The Real Lessons About 3D Printed Face Shields: Effective Engineering Response In Times Of Crisis

April 8, 2020 by Donald Papp 83 Comments

3D printed face shields and other health equipment is big news right now. Not long ago, Prusa Research rapidly designed and manufactured 3D printed face shields and donated them to the Czech Ministry of Health. Their effort is ongoing, and 3D printers cranking out health equipment like the NIH approved design has been peppering headlines ever since.

The Important Part Isn’t 3D Printers

The implied takeaway from all the coverage is that 3D printers are a solution to critical equipment shortages, but the fact that 3D printers are involved isn’t really the important part. We all know printers can make plastic parts, so what should be the real takeaway? The biggest lessons we can learn about Prusa’s ongoing effort are related to how they’ve gone about it.

Continue reading “The Real Lessons About 3D Printed Face Shields: Effective Engineering Response In Times Of Crisis” →

3D Printering: When Resin Printing Gets Smelly

April 7, 2020 by Donald Papp 20 Comments

Nowadays, resin printers are highly accessible and can do some great stuff. But between isopropyl alcohol for part rinsing and the fact that some resins have a definite smell to them, ventilation can get important fast. The manufacturers don’t talk much about this part of the resin printing experience, but it’s there nevertheless. So what can be done when smells become a problem?

I recently had to deal with this when I printed several liters of resin worth of parts. That’s a lot of resin, and a lot of alcohol for part washing. Smells — which had never been much of a problem in my work area — suddenly became an issue.

Where Odors Come From

Smells come from two sources: the resin itself, and the isopropyl alcohol used for cleanup and part washing. Continue reading “3D Printering: When Resin Printing Gets Smelly” →

Flexible Build Platforms Work For FDM, How About SLA?

April 6, 2020 by Donald Papp 6 Comments

Flexible steel sheets as the foundation for build platforms are used to great advantage in FDM 3D printers. These coated sheets are held flat by magnets during printing, and after printing is done the sheet (with print attached) can be removed and flexed to pop the prints free. This got [Jan Mrázek] thinking. He was pretty sure the concept could extend to the build platform on his Elegoo Mars resin printer. With a flexible build platform, troublesome prints could be more easily removed, so he non-destructively modified his printer to have a similar system. [Jan] is clear that this is only a proof of concept, but the test results were good! He printed several jobs that were known to be trouble, and they were all a piece of cake to remove.

[Jan]’s mod consists of a 3D printed, two-piece unit that encapsulates the normal build platform and contains a few strong magnets. A thin sheet of steel sticks flat to this new piece, held in place by the magnets within, and becomes the new build platform. After a print is done, the sheet is removed and [Jan] reports that its flexibility is a big help in removing otherwise troublesome prints, such as the 3D printed solder stencil we covered recently.

[Jan] provides his CAD model but doesn’t really recommend using it for anything other than development work. Results were promising, but there are a number of drawbacks to the prototype. For one thing, it makes the build platform thicker and the Z-axis limit switch needs to be physically lowered in order to zero the unit. Also, the thicker build platform means the volume of resin the build tank can hold is reduced. Still, the idea clearly has merit and shows there absolutely is value in hardware having a hackable design.