Now Toto’s Africa Is Stuck In Our Heads

April 1, 2019 by Brian Benchoff 24 Comments

April Fool’s Day is bad. April Fool’s Day is a terrible, horrible, no good, very bad day. For one day a year, we’re inundated with pieces that can, accurately and without any sense of irony, be called fake news. YouTube is worse. But you know what’s worse than April Fool’s Day? A hundred children playing plastic recorders. But it’s April Fool’s Day, and things must get worse. Here’s a vacuum cleaner playing Africa by Toto.

This is the latest build from [James Bruton] or [Ecks Robots Dot Co Dot UK], who is the king of building just about anything with 3D printers. He’s got a BB8 and some of the cooler Star Wars droids, a Hulkbuster, and openDog. When it comes to confabulating robotics and 3D printers, [James] is the king. But this is April Fool’s Day, and if you’re a big YouTuber, you need to do something annoying. [James] is the king.

This build uses a Henry vacuum cleaner, a canister vacuum with a silk screened face, because why not, and you’re not truly living until you put googly eyes on your Roomba. Also, all vacuums in England are Hoovers, because reasons. In collaboration with [Mothcub], [James] adapted cheap children’s plastic recorders to a Henry vacuum cleaner with a few 3D printed parts, some servo-controlled valves, and a bit of plastic tubing. While using cheap kid’s recorders as the tone generator in what is effectively a pipe organ is interesting (the stickers over the holes are a great idea), this is something that should not be done ever. This idea should not be replicated. These recorders are not in tune and I don’t know how because they’re just one piece of plastic that came out of the same mold.

The servos, and therefore the entire pipe organ, are controlled via MIDI, which makes this the first DIY MIDI pipe organ we’ve seen. It’s a proof of concept, and a pretty good one. It also sounds terrible. This is proof that cheap plastic recorders don’t sound good. The video is below, and I highly suggest skipping the second half.

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Finding Plastic Spaghetti With Machine Learning

March 29, 2019 by Tom Nardi 10 Comments

Among 3D printer owners, “spaghetti” is the common term for the tangled mess of stringy plastic that’s often the result of a failed print. Fear of their print bed turning into a hot plate of PLA spaghetti is enough to keep many users from leaving their machines operating overnight or while they’re out of the house. Accordingly, we’ve seen a number of methods that allow the human operator to watch their print remotely to make sure everything is progressing smoothly.

But unless you plan on keeping your eyes on your phone the entire time you’re out of the house, there’s still a chance some PETG pasta might sneak its way out. Enter the Spaghetti Detective, an open source project that lets machine learning take over when you can’t sit watching the printer all day. Their system plugs into Octoprint to monitor your print in real-time and pause it if it starts looking particularly stringy. The concept is still under development, but judging by the gallery of results submitted by users, the system seems to have a knack for identifying non-edible noodles.

Once the software comes out of beta it looks like the team is going to try to monetize it by providing hosting and monitoring services for a monthly fee, but as it’s an open source project, you’re also able to run the software on your own machine. Though the documentation notes that the lowly Raspberry Pi doesn’t have quite what it takes to handle the image recognition routines, so you’ll need a proper computer if you want to self-host the service. Could be a good use for that old laptop you’ve got kicking around the lab.

As demonstrated in the video after the break, the system’s “spaghetti confidence” is shown with a simple to understand gauge: green is a good-looking print, and red means the detective is getting a sniff of the stringy stuff. If your print dips into the red too much, Octoprint is commanded to pause the print. The user can then look at the last image from the printer and decide to either cancel the print entirely, or resume if the Spaghetti Detective got a little overzealous.

Frankly, it’s a brilliant idea and we’re very interested to see where it goes from here. Assuming you’ve got Octoprint controlling your 3D printer there are some very clever monitoring systems out there currently, but since spaghetti isn’t the only thing a rogue 3D printer can cook up, having an extra line of defense sounds like a good idea to us.

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Casting Car Emblems Via 3D Printing

March 28, 2019 by Lewin Day 10 Comments

Casting is a process that can be quite demanding for the first timer, but highly rewarding once the basic techniques are mastered. It then becomes possible to quickly and reliably produce metal parts en masse, and with impressive tolerances if the right method is chosen. [VegOilGuy] has been experimenting with lost PLA casting, and decided to see if it could be applied to car emblems.

The process begins with 3D models of various car emblems, primarily sourced from Thingiverse. These are printed in PLA, with sprues added to assist with the casting process. The parts are sanded to avoid unsightly print lines on the finished product, and any voids filled with wax. The various emblems are then assembled onto a casting tree, with extra sprues added to improve metal flow with wax and further PLA parts.

The investment mold is then created with plaster, and baked to remove water and melt out the PLA. This is crucial, as any water left in the mold can react explosively with the molten aluminium bronze. The mold is then filled with metal and then allowed to cool. The plaster mold is destroyed, and the parts can then be removed. Final processing involves a trip through a rock tumbler before final polish with sandpaper.

[VegOilGuy] gets impressive results, with the parts looking excellent in their bronze colour. This is an unconventional color for a car emblem, but it’s noted that this material is an excellent candidate for chrome plating to get a more OEM finish.

You might find your lost PLA casting experiments could benefit from the help of a microwave, too. Video after the break.

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Monitor Your 3D Printer With Node-RED And Tasker

March 27, 2019 by Tom Nardi 11 Comments

Anyone with a desktop 3D printer knows that it can be a bit nerve-wracking to leave the machine alone for any extended period of time. Unfortunately, it’s often unavoidable given how long more complicated prints can take. With big prints easily stretching beyond the 20 hour mark, at some point you’re going to need to leave the house or go to sleep. We hope, anyway.

In an effort to make his time away from his printer a bit less stressful, [Mat] from NotEnoughTECH has put together a comprehensive framework for monitoring his machine on the go. After looking at existing remote monitoring solutions, he found none gave him the level of information he was after. His system collects up an incredible number of data points about the printer’s current status and pushes it all to his Android phone as a rich notification. Best of all, he’s documented the entire system in exquisite detail for anyone else who might want to follow in his footsteps.

There’s a considerable amount of hardware and software involved in this system, and getting it up and running won’t be quite as straightforward as using some of the turn-key solutions out there. Octoprint is responsible for controlling and monitoring the printer, and [Mat] is pulling data from its API using Node-RED. That data is formatted and ultimately delivered to his Android device as a notification with Tasker. On the hardware side he’s got a Sonoff POW R2 to not only turn the printer on and off but measure its energy consumption, a USB camera to provide a live view of the printer, and a couple of Raspberry Pis to run it all.

Even if you don’t have a 3D printer, or maybe just don’t leave the house to begin with, the video [Mat] has put together after the break that shows how all the elements of this system are pulled together in Node-RED is a fascinating look at the flow-based visual programming tool. Similarly, it’s a great demonstration on how Tasker can be used to add some very slick Android notifications for your project without having to commit to developing a native application for the platform.

If you like the idea of remotely monitoring your printer but aren’t ready to dive into the deep end like [Mat], there are easier options. With a Raspberry Pi running Octoprint added to your 3D printer and one of the existing mobile monitoring and control front-ends installed, you’ll be well on the way to tackling those big prints without having to pitch a tent in the lab.

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Threaded 3D Printed Part Comparison

March 26, 2019 by Al Williams 25 Comments

If you want to make serious assemblies out of 3D printed parts, you’ll eventually need to deal with threading. The easiest way is to make a nut trap that you can either insert a standard nut into after printing or even during printing. However, there are limitations to this method. If you want a real threaded part you can print the thread, cut the thread with a tap or bolt, or use a threaded insert. [Stefan] ran some tests to see how each of those methods held up to real use. (YouTube, embedded below.) He used fifty test parts to generate data for comparison.

We like the threaded insert method where a brass insert is pushed into the plastic while hot. Special features in the insert cause the brass part to grab the plastic, making it difficult to pull the insert out or twist it within the hole. Another thing we liked was that the tests used holes printed in the horizontal and vertical plane. You can clearly see that the orientation does alter how the holes work and fail to work.

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Volkswagen Tools Turned To The Space Age

March 21, 2019 by Brian Benchoff 36 Comments

The Volkswagen Beetle, and yes the bus and the sexiest car ever made, are cars meant for the people. You can pull the engine out with a strong friend, and you can fix anything in an old Volkswagen. VW realized this, because in the 1950s and ’60s, they came up with plans for tools designed to tear apart an old VW, and these tools were meant to be manufactured in a local shop. That really turns that right to repair on its head, doesn’t it?

While working on his van, [Justin Miller] came across a reference to one of these tools meant to be made at home. The VW 681 is a seal puller, designed to be manufactured out of bar stock. It’s an old design, but now we have interesting tools like 3D printers and parametric CAD programs. Instead of making one of these DIY seal pullers with a grinder, [Justin] brought this tool from the space age into the modern age. He took the design, modelled it in OpenSCAD, and printed it out.

The VW reference book that lists this tool is Workshop Equipment for Local Manufacture, and for this seal puller, it gives perfectly dimensioned drawings that are easily modelled with a few lines of code. The only real trouble is filing down the pointy bit of the puller, but a bit of boolean operations fixed that problem. After 15 minutes of printing and a few hours finding the right documentation and writing fifteen lines of code, [justin] had a plastic VW 681 in his hands. Yes, it was probably a waste of time as a regular seal puller could have done the job, but it’s an excellent example of what can happen when manufacturers support their local repairman.

3D Printing A Combination Lock

March 21, 2019 by Lewin Day 2 Comments

Combination locks! They’re great if you’re skilled at remembering arbitrary strings of numbers, and have a dramatic flair that’s made them a famous part of many a heist movie. They come in a wide variety of styles, and are vulnerable to a different set of attacks than the more typical pin-tumbler locks used on a household basis. If you fancy tinkering with a combination lock, why not 3D print one yourself?

It goes without saying that any lock you 3D print is going to have issues with strength. Such a lock should not be used to protect anything of real value, but it could be handy to prevent the kids getting at the Halloween candy you’re saving for October.

Regardless, 3D printing and assembling your own combination lock is a great way to learn about how they work. It’s a fun project that is also much easier than sourcing and disassembling the real thing. For a greater understanding of the underlying mechanism, this video should make the basic operation clear.

That’s not all 3D printing can offer to the locksport community, of course. You can always print your own keys, too. Video after the break. Continue reading “3D Printing A Combination Lock” →