Gaze Upon This Daft Punk Helmet’s Rows Of Utterly Perfect Hand-Soldered LEDs

September 28, 2018 by Donald Papp 9 Comments

The iconic robot helmets of Daft Punk feature prominently as challenging DIY hardware projects in their own right, and the results never disappoint. But [Nathaniel Stepp]’s photo gallery of his own version really sets the bar in both quality and attention to detail. The helmet uses a Teensy 3.2 as the main processor, and the visor consists of 328 hand soldered through-hole APA106 addressable RGB LEDs. A laser cut panel serves as the frame for the LEDs, and it was heat-formed to curve around the helmet and mate into the surrounding frame. Each LED is meticulously hand-soldered, complete with its own surface mount decoupling cap; there’s no wasted space or excess wire anywhere to be seen. It looks as if a small 3D printed jig was used to align and solder the LEDs one or two columns at a time, which were then transferred to the visor for final connections with the power bus and its neighboring LEDs.

After the whole array was assembled and working, the back of each LED appears to have then been carefully coated in what looks like Plasti-Dip in order to block light, probably to minimize the blinding of the wearer. A small amount of space between each LED allows the eyeballs inside the helmet to see past the light show in the visor.

The perfectly done array of LEDs in the visor is just one of the design elements showing the incredible workmanship and detail in [Nathaniel]’s helmet. His website promises more build details are coming, but in the meantime you can drink in the details shown in the aforementioned photo gallery.

With Halloween approaching, you might be interested in rolling your own Daft Punk inspired helmet. Not ready to do everything from scratch? No problem, because it’s never been easier to make your own with the help of a 3D printer and some LED strips.

[via SparkFun Blog]

Maker Faire NY: Infinite Autonomous 3D Printing

September 27, 2018 by Brian Benchoff 7 Comments

Although it’s not an idea that has yet trickled down to $200 printers drop-shipped from China, one of the most innovative ideas in the 3D printing world in the last few years is putting plastic down on a conveyor belt. Yes, MakerBot was doing it back in 2010, but we’re not going to talk about that. Printing on a conveyor belt instead of a static bed allows you to easily print multiples of an object autonomously, without any human interaction. If you’re really clever, you could rotate the hot end 45° and build a piece of plastic that is infinitely long, like the printer [Bill Steele] built, the Blackbelt, or ‘the CAD files might exist somewhere’ Printrbot infinite build volume printer.

At this year’s World Maker Faire, we didn’t see an infinite printer, but we did catch a glimpse of an idea that could reliably take 3D printers into production. It’s a Multiprinter Autonomous 3D Printer, designed and built by [Thomas Vagnini].

The idea of using 3D printers for production and manufacturing is a well-studied problem. Lulzbot has a heated room filled with printers they use to manufacture all their machines. Prusa’s manufacturing facility is similarly well-equipped. However, both of these setups require helper monkeys to remove a part from the bed and set the machine up for the next print.

Instead of a strictly manual process, [Thomas]’ machine uses a sort of cartridge-based system for the printing bed. The glass beds are stored in a cassette, and for the first print, the printer pulls a bed onto the heated build plate through a system of conveyors. When the print is finished, the part and the bed ar fed into a rotating cassette, where it can be removed by a tech, prepped for the next print, and placed back in the ‘bed feeder’. It’s a system that brings the manual intervention cycle time of a 3D printer down to zero. If you’re producing hundreds of parts, this will drastically speed up manufacturing.

While it is a relatively niche idea, this is a very well-designed machine. It’s all laser cut, uses core-XY mechanics, and with the right amount of tuning, it does exactly what it says it will do. It’s not for everybody, but that’s sort of the point of manufacturing parts on a 3D printer.

Prusa Introduces A Resin Printer At Maker Faire NY

September 22, 2018 by Brian Benchoff 35 Comments

For one reason or another, the World Maker Faire in New York has become the preeminent place to launch 3D printers. MakerBot did it with the Thing-O-Matic way back when, and over the years we’ve seen some interesting new advances come out of Queens during one special weekend in September.

Today Prusa Research announced their latest creation. It’s the resin printer you’ve all been waiting for. The Prusa SL1 is aiming to become the Prusa Mk 3 of the resin printer world: it’s a solid printer, it’s relatively cheap (kit price starts at $1299/€1299), and it produces prints that are at least as good as resin printers that cost three times as much.

The tech inside the SL1 is about what you’d expect if you’ve been following resin printers for a while. The resin is activated by a bank of LEDs shining through a photomask, in this case a 5.5 inch, 1440p display. Everything is printed on a removable bed that can be transferred over to a separate ‘curing chamber’ after the print is done. It’s more or less what you would expect, but there are some fascinating refinements to the design that make this a resin printer worthy of carrying the Prusa name.

Common problems with a masked SLA printer that uses LEDs and an LCD are the interface between the LCD and the resin, and the temperature of the display itself. Resin is not kind to LCD displays, and to remedy this problem, Prusa has included an FEP film on the bottom of the removable tank. This is a user-replaceable part (technically a consumable, at least to the same extent as a PEI build plate on a filament printer), and Prusa will be selling those as spare parts on their store. The LCD is also cooled; one of the major drawbacks of shining several watts of UV through an LCD is the lifetime of the display. Cooling the display helps, and should greatly increase the lifetime of the printer. All of this is wrapped up in an exceptionally heavy metal case with the lovely hinged UV-opaque orange plastic lid.

Of course, saying you’ve built a resin printer is one thing, but how do the prints look? Exceptional. The Prusa booth at Maker Faire was loaded up with sample prints from the machine, and they’re of the same high quality you would expect from the Form 3D printers that have been the go-to in the resin printer world. The Prusa SLA also works with big-O Open resins, meaning you’re not tied to a single resin vendor.

This is just the announcement of the Prusa resin printer, but they are taking preorders. The price for the kit — no word on how complex of a kit it is — is $1300, while the assembled printer is $1600, with the first units shipping in January.

Prusa Unveils Their Own Line Of PLA Filament

September 21, 2018 by Tom Nardi 33 Comments

There’s little debate that the Original Prusa i3 MK3 by Prusa Research is just about the best desktop 3D printer you can buy, at least in its price bracket. It consistently rates among the highest machines in terms of print quality and consistency, and offers cutting edge features thanks to its open source iterative development. Unless you’re trying to come in under a specific budget, you really can’t go wrong with a Prusa machine.

But while the machine itself can be counted on to deliver consistent results, the same can’t always be said for the filament you feed into it. In a recent blog post, [Josef Prusa] explains that his team was surprised to see just how poor the physical consistency was on even premium brands of 3D printer filament. As a company that prides itself with keeping as much of the 3D printing experience under their control as possible, they felt they had an obligation to do better for their customers. That’s why they’ve started making their own filament which they can hold to the same standards as the rest of their printer.

Their new filament, which is aptly called “Prusament”, is held to higher physical standards of not only diameter but ovality. Many manufacturers simply perform spot checks on the filament’s diameter, but this can miss bulges or changes in its cross-sectional shape. On your average 3D printer this might cause some slightly uneven extrusion and a dip in print quality, but likely not a failure. But the Prusa i3 MK3, specifically with the Multi Material upgrade installed, isn’t most printers. During testing even these slight variations were enough to cause jams.

But you won’t have to take their word for it. Every spool of Prusament will have a QR code that points to a page which tells you the exact production date, length, percent ovality, and standard diameter deviation of that particular roll. An interactive graph will even allow you to find the filament’s diameter for a specific position in the spool, as well as determine how much filament is remaining for a given spool weight. It should be very interesting to see what the community will do with this information, and we predict some very interesting OctoPrint plugins coming down the line.

Prusament is currently only available in PLA, but PETG and ASA variants are coming soon. You can order it now directly from Prusa Research in Prague for $24.99 per kilogram, but it will also be available on Amazon within the month for help keep the shipping costs down.

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The N64 Controller Gets Brass Gears Through 3D Printing

September 21, 2018 by Brian Benchoff 36 Comments

The controller for the Nintendo 64 is a masterpiece of design, and despite being more than two decades old, people are still using this controller competitively. Smash Bros, you know. Those competitive gaming enthusiasts are hard on their controllers, and after decades and tournaments, the analog stick will wear out. Previously, this required a rebuild or simply replacing the entire controller. Now there’s another option: a completely re-engineered analog stick, all made possible thanks to 3D printing.

[Nam Le] is a student at Cal Poly, and as would be expected for a very specific subset engineering students, had to track down new N64 controller every few months. The stick on these controllers wear out, so [Nam] decided to make the most durable joystick that has ever fit inside an N64 controller.

The design of the N64 stick is pretty simple, and exactly what you would expect if you’ve ever opened up an analog joystick. There’s the stick itself, which is connected to gears on the X and Y axes, which are in turn connected to encoders. This entire assembly sits in a bowl. After twenty years, the mating surface between the stick and the gears wear down, and the bowl becomes deformed. The solution here is obviously to engineer something sturdier, and despite what most of the 3D printing community will tell you, ABS and PLA just won’t cut it.

[Nam] re-designed the gears and bowl out of brass using lost-wax casting using 3D printed parts. These brass parts were mated with 3D printed gears and an enclosure for the bowl. The stick is nylon, an important design choice because this is the first part to wear down anyway, and it’s also the easiest part to replicate. Yes, this is designing an analog stick for the strength of materials and Real Engineering™ for those of you keeping track at home.

Right now, the joystick works as intended, and lasts much longer than the stock version. The goal now is to get this stick tournament-legal for some serious Smash time, in the hopes of not replacing controllers every few months.

Industrial 3D Printing Uses Layers Like We’ve Never Seen Before

September 19, 2018 by Mike Szczys 20 Comments

We’ve seen FDM printers lay down layers by extruding plastic in a line. We’ve seen printers use sintering and lithography to melt or cure one layer at a time before more print medium moves into place for the next layer. What we’ve never seen before is a printer like this that builds parts from distinct layers of substrate.

At the International Manufacturing Technology Show last week I spoke with Eric of Impossible Objects. The company is using a “sheet lamination process” that first prints each layer on carbon fiber or fiberglass, then uses a hydraulic press and an oven to bake the part into existence before bead-blasting the excess substrate away. Check out my interview with Eric and join me below for more pictures and details.

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3D Printing In Metal: The Laser And Metal Powder Printers We Saw At IMTS

September 17, 2018 by Mike Szczys 24 Comments

Last week I went to the International Manufacturing Technology Show (IMTS) and it was incredible. This is a toy store for machinists and showcases the best of industrial automation. But one of the coolest trends I found at the show are all the techniques used to 3D print in metal. The best part is that many of the huge machines on display are actually running!

It’s probably better to refer to this as additive manufacturing, because the actual methods can be significantly different from your 3D printer. Below you’ll find examples of three different approaches to this process. I had a great interview with a company doing actual 3D printing in metal using a nozzle-based delivery often called cladding. There’s a demo video of powder layer printing using lasers. And a technique that uses binders as an intermediary step toward the final metal part. Let’s take a look!

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