Bird Beats Cancer With The Help Of A 3D-Printed Prosthetic

October 11, 2018 by Dan Maloney 12 Comments

It’s a reasonable certainty that 3D-printing is one day going to be a huge part of medicine. From hip implants to stents that prop open blood vessels to whole organs laid down layer by layer, humans will probably benefit immensely from medical printing. But if they do, the animals will get there first; somebody has to try this stuff out, after all.

An early if an unwilling adopter of 3D-printed medical appliances is [Jary], a 22-year-old Great Pied Hornbill, who recently received a 3D-printed replacement for his casque, the large, mostly hollow protuberance on the front the bird’s skull leading out over the upper beak. There’s no known function for the casque, but it had to be removed since cancer was destroying it and [Jary] wouldn’t have fared well post-surgically without one. Working from CT scans, the veterinary team created a model of the casque as well as a jig to guide the saw during surgery. There’s no word on what filament was used, but we’d guess PLA since it’s biocompatible and available in medical grades. The video below shows some of the surgery; it’s interesting to note that the prosthetic started out natural colored but quickly turned yellow as [Jary] preened with oils from glands near his tail feathers, just like a natural casque would.

Hornbills live to about 40 years old, so [Jary] is just middle-aged. Here’s hoping that he lives a long, happy life in return for being a pioneer in 3D-printing for medical and surgical appliances.

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The 3D Printed Guitar

October 10, 2018 by Brian Benchoff 6 Comments

We just wrapped up the Musical Instrument Challenge in the Hackaday Prize, and that means we’re sorting through a ton of inventive electronic musical instruments. For whatever reason we can’t seem to find many non-electronic instruments. Yes, MPCs are cool, but so are strings and vibrating columns of air. That’s what makes this entry special: it’s a 3D printed physical guitar. But it’s also got a hexaphonic pickup, there are lights in the fretboard, and it talks to a computer for PureData processing.

First, the construction of this guitar. It’s mostly 3D printed, with the ‘frame’ of the body made in a Creality 3D printer. It’s a bolt-on neck with a telecaster body, but the core of this guitar — where the pickups and bridge attach — are made out of aluminum extrusion. Another piece of aluminum extrusion runs down the neck, which is clad in a 3D-printed ‘back’ that looks ‘comfortable enough’. The headstock is bolted onto the end of this neck, and it seems reasonably tolerant of having a hundred pounds or so of strings pulling on it. The bridge is also 3D printed, with the saddles integrated into the print. Conventional wisdom says this would sound terrible, but nylon saddles were a thing back in the day, so we’re just going to roll with it.

The electronics are where this project really shines. The pickup is a salvaged Roland GK3 hexaphonic deal, with six outputs for each string. This is sent into a Teensy with an audio path for each individual string. Audio processing happens in the guitar, and latency is under five milliseconds, which is quick enough to not be a terrible distraction.

Except for synths and drum machines and computers, the last fifty or so years of technological progress hasn’t really made it to the world of musical instruments. Guitarists, especially, are technophobes who hate everything invented after 1963. While the neck of [Frank]’s ElektroCaster probably doesn’t feel great, this is a really interesting instrument and a great entry to the Hackaday Prize.

3D Printed Catamaran Eats Benchy’s Lunch

October 10, 2018 by Tom Nardi 18 Comments

If we’ve learned anything, it’s that 3D printers are exceptionally well suited to printing little boats. According to the Internet, 3D printers are at their best when pumping out cute PLA boats in all the colors of the rainbow; perfect for collecting dust on a shelf somewhere. Ask not what your Benchy can do for you, ask what you can do your Benchy.

But this 3D printed boat isn’t so cute and cuddly. In fact, it’s an absolute beast. Built by [Wayne Andrews], this nearly meter long 3D printed racing catamaran looks more Batman than Popeye. In the video after the break you can see a recent run of the boat on the lake, and we think you’ll agree it definitely has the performance to back up its fierce looks.

Impressively, the hull isn’t printed out of some expensive high-tech filament. It’s the cheapest PLA [Wayne] could get his hands on, and glued together with nothing more exotic than Loctite Super Glue Gel. The secret is the internal “West System” fiberglass cloth and resin work, which is the same stuff used on real boat hulls. It took about 5 days of continuous printing to produce all the pieces needed to assemble the hull, which is a scaled up version of a design by [Thomas Simon].

The internal layout is about what you’d expect in a fast RC boat. It’s running on a 1900 Kv motor powered by dual 6S batteries and a water cooled 180 A Seaking ESC which provides 5 BHP to the Octura x452 propeller. On the business end of his boat, [Wayne] used a commercial aluminum strut and rudder unit. Running gear printed out of something strong like nylon would be an interesting experiment, but perhaps a tall order for this particular motor.

We recently covered a 3D printed jet boat that’s no slouch either, but if you’re looking for a more relaxed ride you could always 3D print a FPV lifeboat.

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Printrbot Post Mortem

October 10, 2018 by Al Williams 48 Comments

For many people, Printrbot was their first 3D printer. What started out as [Brook Drumm’s] Kickstarter idea to make 50 printers turned into over a thousand orders backlogged. To quote [Brook], they went from zero sales to about two million in the first year and then twelve million a few years later. As is often the case, though, the rapid scale-up didn’t survive a drop in sales. [Thomas Sanladerer] has a great interview video with [Brook] and you can see it below.

It is both nostalgic and sad to see the Printrbot headquarters all empty with quiet machines. [Brook] was always one of us and often gave back to the community and it is interesting to hear his perspective about what brought his company to an end.

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Knock Your 3D Printer Down To 2D

October 8, 2018 by Tom Nardi 15 Comments

Hackers love 3D printers. In fact, they might love them a little too much. We ~~hope~~ know we aren’t be the only ones who couldn’t turn down a good deal on an overseas printer (or two). But when you’re not pumping out plastic boats and other PLA dust collectors, what are you supposed to do with them?

Well if you’re like [Uri Shaked] you could hand them a pen and tell them to get writing. The holidays are coming up quick, and somebody’s gotta sign all these cards. In his detailed write-up, he shows how he was able to add a pen to his Creality CR-10 printer to turn it into a lean mean letter-writing machine without making any permanent changes to the printer.

The physical aspect of this hack is about as simple as they come: just come up with some way to hold the pen a bit below the printer’s hotend. The positioning here is a bit critical, as you don’t want to crash the nozzle into the bed while writing out a missive. [Uri] got fancy and designed a little bracket that clamps onto the CR-10 and even has a M3 screw to hold the pen in place, but you could get away with zip ties if you just want to experiment a bit.

[Uri] goes into much greater detail on the software side of things, which is good, as it does take a bit of Inkscape trickery to get the printer to perform the specific dance moves required. He goes through step by step (with screen shots) explaining how to set up Orientation Points and configure the tool parameters for optimal performance. Even if you aren’t looking to put a 3D printer to work autographing your 8x10s before the next hackerspace meet, this is an excellent guide on producing GCode with Inkscape which can be helpful for tasks such as making PCBs.

The general process here is very similar to adding a laser module to your 3D printer, but with considerably lower risk of your eyeballs doing their best Death Star impression.

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Perhaps The Ultimate Raspberry Pi Case: Your PC

October 5, 2018 by Al Williams 31 Comments

One of the great joys of owning a 3D printer is being able to print custom cases for boards like the Raspberry Pi. What’s more, if you are using a desktop PC, you probably don’t have as many PCI cards in it as you used to. Everything’s moved to the motherboard. [Sneekystick] was using a Pi with a PC and decided the PC itself would make a great Pi case. He designed a bracket and it looks handy.

The bracket just holds the board in place. It doesn’t connect to the PC. The audio, HDMI, and power jacks face out for access. It would be tempting and possible to power the board from the PC supply, but to do that you have to be careful. Connecting the GPIO pins to 5V will work, but bypasses the input protection circuitry. We’ve read that you can find solder points near the USB plug and connect there, but if you do, you should block out the USB port. It might be nice to fill in that hole in the bracket if you planned to do that.

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3D Printed Sneakers Are Now A Thing

October 5, 2018 by Lewin Day 20 Comments

Shoes may seem simple at face value, but are actually rather complex. To create a comfortable shoe that can handle a full day of wear without causing blisters, as well as deal with the stresses of running and jumping and so on, is quite difficult. Is it possible to create a shoe that can handle all that, using a 3D printer?

[RCLifeOn] discovered these sneakers by [Recreus] on Thingiverse, and decided to have a go printing them at home. While [Recreus] recommend printing the shoes in their Filaflex material, for this build, one shoe was printed in thermoplastic polyurethane, the other in Ninjaflex. As two filaments that are both commonly known to be pliable and flexible, the difference in the final parts is actually quite significant. The Ninjaflex shoe is significantly more flexible and cushions the foot better, while the rigidity of the TPU shoe is better for ankle support.

Our host then takes the shoes on a long run through the woods, battling dirt, mud, and other undesirables. Both shoes hold up against the abuse, although [RCLifeOn] notes that the Ninjaflex shoe is much more comfortable and forgiving for longer duration wear.

We’ve seen other 3D printed shoe hacks before, too – like these nifty shoelace locks.