FOSDEM Saved, With 3D Printing

February 9, 2024 by Jenny List 23 Comments

If you were to consider what the most important component of a hacker event might be, the chances are you’d pick something that’s part of the program, the ambiance, or the culture. But as the organizers of FOSDEM in Brussels found out, what’s really the most important part of such an event is the toilet paper.

If you can’t keep the supplies coming, you’re in trouble, and since they only had one key for the dispensers across the whole event, they were heading for a sticky situation. But this is a hacker event, and our community is resourceful. The folks on the FreeCAD booth created a model of the key which they shared via the Ondsel collaboration tools, while those on the Prusa booth fired up their Prusa XL and ran off a set of keys to keep the event well supplied.

Perhaps for many of us, the act of running off a 3D model and printing it is such a mundane task as to be unremarkable — and indeed the speed at which they were able to do it points to it being a straightforward task for them. But the sight of a bunch of hardware hackers saving the event by doing what they do best is still one to warm the cockles of our hearts. We’re fairly certain it’s not the first time we’ve seen a bit of clandestine venue hacking save an event, but perhaps for the sake of those involved, we’d better not go into it.

3D Printing Silicone Parts

February 8, 2024 by Al Williams 6 Comments

Silicone is a useful material for many purposes. Traditionally, creating something out of silicone required injection molding. That’s not difficult, but it does require a good bit of setup. As [Formlabs] points out in a recent video, there are at least three other routes to create silicone parts that utilize 3D printing technology that might fit your application better, especially if you only need a few of a particular item. You can see the video below.

The three methods are either printing silicone directly, printing a mold, casting silicone, or using high-performance elastomers, which are very silicone-like. Of course, as you might expect, some of this is aimed at prompting some of [Formlab’s] products, like a new silicone resin, and you can’t blame them for that.

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Your 1983 Video Phone Is Finally Ready

February 7, 2024 by Al Williams 8 Comments

If you read Byte magazine in 1983, you might have expected that, by now, you’d be able to buy the red phone with the video screen built-in. You know, like the one that appears on the cover of the magazine. Of course, you can’t. But that didn’t stop former Hackaday luminary [Cameron] from duplicating the mythical device, if not precisely, then in spirit. Check it out in the video, below.

While the original Byte article was about VideoTex, [Cameron] built a device with even more capability you couldn’t have dreamed of in 1983. What’s more, the build was simple. He started with an old analog phone and a tiny Android phone. A 3D-printed faceplate lets the fake phone serve as a sort of dock for the cellular device.

That’s not all, though. Using the guts of a Bluetooth headset enables the fake phone’s handset. Now you can access the web — sort of a super Videotex system. You can even make video calls.

There isn’t a lot of detail about the build, but you probably don’t need it. This is more of an art project, and your analog phone, cell phone, and Bluetooth gizmo will probably be different anyway.

Everyone always wanted a video phone, and while we sort of have them now, it doesn’t quite seem the same as we imagined them. We wish [Cameron] would put an app on the phone to simulate a rotary dial and maybe even act as an answering machine.

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Common Enzyme Breaks Down PLA Fast

February 4, 2024 by Lewin Day 50 Comments

The global issue of plastic waste has prompted scientists to seek innovative solutions for recycling. Single-use plastics, notorious for their environmental impact, require new methods for efficient and sustainable management. For some common plastics, though, salvation could be at hand, with researchers identifying a common enzyme that can be used to break them down fast.

Researchers at King’s College London have discovered an enzyme used in laundry detergents that can break down PLA plastics within 24 hours, using a little heat as an aid. Normally, this is achieved via composting methods that take weeks or months. This method transforms the plastics back into their original chemical components, offering a rapid and eco-friendly recycling process. The monomers can then be reused for manufacturing new plastic items.

One wonders if this could also be used in another way – perhaps in a multimaterial printer, allowing PLA to be used for supports and then broken down. It’s probably not that necessary, given other degradable materials exist, but it’s something to think about.

This project is a significant leap forward in recycling technology, showcasing the potential for enzymes to revolutionize how we handle plastic waste. It could also be a great way to recycle all those errant deformed Pikachus that keep ending up in your hackerspace’s 3D-printing waste basket. In any case, plastic waste is a problem the world needs to solve, and quickly, because it’s not going anywhere any time soon. Video after the break.

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Tricky 3D Printed Joinery Problem? Give Heat Staking A Try

February 3, 2024 by Dan Maloney 15 Comments

When you just can’t 3D print something as a monolithic part, you’re going to have to join pieces together. In such cases, most of us instinctively include threaded inserts or nut slots in the design, or even reach for a tube of CA glue. But perhaps you should be thinking more along the lines of heat-staking your printed parts together.

Although you might not be familiar with the term, if you’ve looked inside anything made out of plastic, chances are good you’ve seen a heat-staked joint. As [Richard Sewell] explains, a heat-staked joint is nothing more than the classic mortise-and-tenon made from plastic where the tenon stands proud of the joint face so it can be softened with heat. The tenon spreads out so the joint can’t be pulled apart. A variant on the theme includes a mortise with a generous chamfer so the melted tenon can spread out, providing not only extra resistance to pull-out be also a more flush surface.

To melt the joint, [Richard] simply uses a soldering iron and a little pressure. To spread out both the heat and the force a bit, he uses the barrel of the iron rather than a tip, although we could see a broad chisel tip being used for smaller joints. Either way, a layer of Kapton tape helps keep the iron from getting gunked up with melted plastic. [Richard] lists a host of advantages for this kind of plastic joinery, including eliminating the need for additional hardware. But we think the best feature of this joint is that by avoiding monolithic prints, each aspect of a part can have its layer lines optimized.

While it probably isn’t applicable everywhere, heat-staking looks like a technique to keep in mind. We’d love to see [Stefan] over at CNC Kitchen do some of his testing magic on these joints, like he did for threaded inserts.

An Alternative Orientation For 3D Printed Enclosures

February 2, 2024 by Danie Conradie 29 Comments

When it comes to 3D printing, the orientation of your print can have a significant impact on strength, aesthetics, and functionality or ease of printing. The folks at Slant 3D have found that printing enclosures at a 45° provides an excellent balance of these properties, with some added advantages for high volume printing. The trick is to prevent the part from falling over when balance on a edge, but in the video after the break [Gabe Bentz] demonstrate Slant 3D’s solution of minimalist custom supports.

The traditional vertical or horizontal orientations come with drawbacks like excessive post-processing and weak layer alignment. Printing at 45° reduces waste and strengthens the end product by aligning the layer lines in a way that resists splitting across common stress points. When scaling up production, this orientation comes with the added advantage of minimal bed contact area, allowing the printer to auto-eject the part by pushing it off the bed with print head.

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The Case Against Calibration Cubes

February 2, 2024 by Danie Conradie 27 Comments

Calibration cubes have long been a staple for testing and adjusting 3D printers, but according to [Stefan] of CNC Kitchen, they’re not just ineffective—they could be leading us astray. In the video after the break he explains his reasoning for this controversial claim, and provides a viable alternative.

Such cubes are often used to calibrate the steps per millimeter for the printer’s steppers, but the actual dimensions of said cube can be impacted by over or under extrusion, in addition to how far the machine might be out of alignment. This can be further exacerbated by measuring errors due to elephant’s foot, over extruded corners, or just inaccuracies in the caliper. All these potential errors which can go unnoticed in the small 20 x 20 mm cube, while still leading to significant dimensional errors in larger prints

So what’s the solution? Not another cube. It’s something called the “CaliFlower” from [Adam] of Vector 3D. This is not a typical calibration model — it’s carefully designed to minimize measurement errors with ten internal and external measuring points with stops for your calipers. The model costs $5, but for your money you get a complete guide and spreadsheet to calculate the required of corrections needed in your firmware or slicer settings.

If you regularly switch materials in your 3D printer, [Stefan] also advises against adjusting steps per millimeter and suggests defining a scaling factor for each material type instead. With this method validated across different materials like PLA, PETG, ABS, and ASA, it becomes evident that material shrinkage plays a significant role in dimensional inaccuracy, not just machine error. While [Stefan] makes a convincing case against the standard calibration cube for dimensional calibration, he notes that is is still useful for evaluating general print quality and settings.

[Stefan] has always done rigorous testing to back his claims, and this video was no different. He has also tested the effects of filament color on part strength, the practicality of annealing parts in salt, and even printing custom filament.

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