ERRF 18: The Start Of Something Great

July 18, 2018 by Tom Nardi 7 Comments

For years, the undisputed king of desktop 3D printing conferences has been the Midwest RepRap Festival (MRRF). Hosted in the tropical paradise that is Goshen, Indiana, MRRF has been running largely unopposed for the top spot since its inception. There are other conferences focused on the industrial and professional end of the 3D printing spectrum, and of course you’d find a Prusa or two popping up at more or less any hacker con; but MRRF is focused on exploring what the individual is capable of once they can manifest physical objects from molten plastic.

But on June 23rd, 2018, MRRF finally got some proper competition. As the name might indicate, the East Coast RepRap Festival (ERRF) is an event very much inspired by its Hoosier State predecessor. Held in Bel Air, Maryland, hackers on the right side of the United States for the first time had the opportunity to attended a true 3D printing festival without having to get on a plane. Not to say it was a neighborhood block party; people from all over the country, and indeed the globe, descended on the APG Federal Credit Union Arena for the two-day celebration of everything plastic.

This inaugural ERRF was, to put it mildly, a massive success. A couple of Hackaday Field Agents were in attendance, and we definitely came away impressed with the event considering it was the first attempt. We saw evidence that the RepRap dream of printable printers is still going strong, a gaggle of new printers and products that will be prying at your wallet this year, and an American-made hotend that challenges traditional wisdom. Of course we also saw a huge number of 3D printing fanatics who were eager to show off their latest creations.

We have no doubt that ERRF will return again next year, but until then, you’ll have to settle for the following collection of selected highlights from this year’s show.

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3D Printer Guardian Watches For Worst-case Failures

July 16, 2018 by Donald Papp 17 Comments

Some devices have one job to do, but that job can have many facets. To [jmcservv], an example of this is the job of protecting against worst-case failures in a 3D printer, and it led him to develop the 3D Printer Watchdog Guardian. When it comes to fire, secondary protection is the name of the game because it’s one thing to detect thermal runaway and turn off a heater, but what if that isn’t enough? The MOSFET controlling the heater could have failed closed and can no longer be turned off in a normal sense. In such cases, some kind of backup is needed. Of course, a protection system should also notify an operator of any serious problem, but what’s the best way to do that? These are the kinds of issues that [jmcservv] is working to address with his watchdog, which not only keeps a careful eye on any heating elements in the system, but can take a variety of actions as a result.

Some outcomes (like fire) are bad enough that it’s worth the extra work and cost of additional protection, and that’s the thinking that has led [jmcservv] to submit his watchdog system for The Hackaday Prize.

Watney: A Fully 3D Printed Rover Platform

July 15, 2018 by Tom Nardi 9 Comments

We’re getting to the point that seeing 3D printed parts in a project or hack isn’t as exciting as it was just a few years ago. The proliferation of low-cost desktop 3D printers means that finding a printer to squirt out a few parts for your build isn’t the adventure it once was. Gone are the days of heading to a local hackerspace or college hoping their janky Mendel felt like working that day. But all that really means is that hackers and makers now have the ability to utilize 3D printing even more. Forget printing one or two parts of your design, just print the whole thing.

That’s exactly what [Nik Ivanov] did with Watney, his fully 3D printed rover project. After lamenting that many so-called 3D printed rovers were anything but, he set out to design one that was not only made primarily of printed parts, but was robust enough to put some real work in. Over the course of several design iterations, he built a very capable all-wheel drive platform that needs only some electronics and a handful of M3 screws to leap into action.

As long as you’ve got a 3D printer big enough to handle the roughly 120mm x 190mm dimensions of this bot’s body, you’re well on the way to owning your very own video rover. [Nik] recommends printing everything in PETG, no doubt for its increased strength when it comes to things like the drive gears. Plus it’s low warp, which is really going to help when printing the top and bottom sections of the body. TPU is advised for the tires, but if you don’t have any (or your printer chokes on flexible filaments) you can just wrap the wheels with wide rubber bands.

[Nik] is using a Raspberry Pi Zero W as the brains of the operation, but the beauty of an open platform like this is that you could easily swap out the controls for something else to meet your needs. In addition to the Pi, there’s a L298N H-bridge motor controller to interface with the dual geared motors, as well as a servo to provide tilt for the SainSmart camera module.

We’ve often been surprised at just how expensive commercial robotics platforms can be, so we’re keenly interested in seeing if the availability of designs like this spur on DIY rover development. Though if you’re looking for something a little more rough and tumble, we’ve seen a 3D printed rover that looks combat-ready.

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3D Printed Variable Area Jet Nozzle

July 14, 2018 by Tom Nardi 8 Comments

If you’ve ever seen the back end of a military jet, you’ve likely seen variable area nozzles. They’re used to adjust the exhaust flow out of the rear of a jet engine during supersonic flight and while the afterburner is engaged. Commercial aircraft, with the exception of the Concorde, don’t need such fancy hardware since a static exhaust nozzle works well enough for the types of flying they’ll be doing. For much the same reasons, RC aircraft don’t need variable area nozzles either, but it doesn’t keep builders from wanting them.

Which brings us to this utterly gorgeous design by [Marco Colucci]. Made up of 23 individual PETG parts, this variable area nozzle is able to reduce its diameter by 50% with just a twist of the rotating collar. When paired with a hobby servo, this mechanism will allow the operator to adjust the nozzle aperture with an extra channel on their RC transmitter. The nozzle hasn’t flown yet, but a test run is being planned with a 40mm Electric Ducted Fan (EDF) motor. But thanks to the parametric design, it shouldn’t be a problem to scale it up to larger motors.

But the big question: does it have an effect on the EDF’s performance? The answer is, of course, no. This doesn’t actually do anything. An EDF motor has no need for this sort of nozzle, and even if you tried to fit this on a scale jet engine, it would melt in seconds from the exhaust temperature. This is purely a decorative item, to give the plane a more accurate scale look. To that end, it looks fantastic and would definitely be impressive on the back of a large scale RC military fighter.

If anything, [Marco] says he expects performance to be worse with the nozzle fitted. Not only is it adding dead weight to the plane, but restricting the air coming out of the back of the fan isn’t going to do anything but reduce thrust. But on the bright side: if it’s flying slower, it will be easier to see how awesome your adjustable nozzles look.

This isn’t the first time somebody’s tried to make an electric RC plane look like it’s packing a proper turbine, but it certainly might be one of the slickest. Only way to top this is to build an actual jet engine for the thing.

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Casting A 3D Printed Extruder Body In Aluminum

July 14, 2018 by Al Williams 33 Comments

Creating 3D prints is great, but sometimes you need something more durable. [Myfordboy] printed a new 3D printer extruder in PLA and then used the lost PLA method to cast it in aluminum. You can see the results in the video below.

The same process has been used for many years with wax instead of PLA. The idea is to produce a model of what you want to make and surround it with a material called investment. Once the investment sets, heat melts the PLA (or wax) leaving a mold made of the investment material. Once you have the mold, you can place it in a frame and surround it with greensand. Another frame gets a half pipe placed and packed with greensand. The depression made by this pipe will provide a path for the metal to flow into the original mold. Another pipe will cut a feeder into the greensand over this pipe.

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ERRF 18: New Products Make Their Debut

July 13, 2018 by Tom Nardi 6 Comments

While ostensibly the purpose of the recent East Coast RepRap Festival (ERRF) was to celebrate the 3D printing community and culture, it should come as no surprise that more than a few companies decided to use the event as an opportunity to publicly launch new products. Who can blame them? It’s not as if every day you have a captive audience of 3D printing aficionados; you might as well make the best of it.

Many creations were being shown off for the first time at ERRF, and we surely didn’t get a chance to see them all. There was simply too much going on at any given time to be sure no printed stone was left unturned. But the following printers, filaments, and accessories caught our attention long enough to warrant sharing with the good readers of Hackaday.

Keep in mind that much of this information is tentative at best, and things could easily change between now and when the products actually go on sale. These events serve as much as a sounding board for new products as they do a venue for advertising and selling them, so feedback received from show attendees may very well alter some of these products from what we saw at ERRF.

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Supersize DIY R/C Servos From Windscreen Wipers

July 13, 2018 by Ben James 26 Comments

We’re all familiar with the experience of buying hobby servos. The market is awash with cheap clones which have inflated specs and poor performance. Even branded servos often fail to deliver, and sometimes you just can’t get the required torque or speed from the small form factor of the typical hobby servo.

Enter [James Bruton] and his DIY RC servo from a windscreen wiper motor. Windscreen wiper motors are cheap as chips, and a classic salvage. The motor shaft is connected to a potentiometer via a pulley and some string, providing the necessary closed-loop feedback. Instead of using the traditional analog circuitry found inside a servo, an Arduino provides the brains. This means PID control can be implemented on the ‘duino, and tuned to get the best response from different load characteristics. There’s also the choice of different interfacing options: though [James]’ Arduino code accepts PWM signals for a drop-in R/C servo replacement, the addition of a microcontroller means many other input signal types and protocols are available. In fact, we recently wrote about serial bus servos and their numerous advantages.

We particularly love this because of the price barrier of industrial servomotors; sure, this kind of solution doesn’t have the precision or torque that off-the-shelf products provide, but would be sufficient for many hacks. Incidentally, this is what inspired one of our favourite open source projects: ODrive, which focuses on harnessing the power of cheap brushless motors for industrial use.

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