Boredom + Lasers = Projector!

August 29, 2017 by James Hobson 7 Comments

[Krazer], a post-doctoral researcher at MIT, loves him some lasers. When out of boredom one afternoon he hatched an idea for a laser projector, it grew until a few years later he wound up with this RGB laser for a projector — Mark IV no less.

In addition to 3D-printing the parts, the major innovation with this version is the ability to re-align the lasers as needed; tweaking the vertical alignment is controlled by a screw on the laser mounts while the horizontal alignment is done the same way on the mirror mounts. This simplifies the design and reduces the possibility of part failure or warping over time. An additional aluminium base epoxied to the projector aims to keep the whole from deforming and adds stability. With the help of a mirror for the final alignment — sometimes you must use what you have— the projector is ready to put on a show.

True to the spirit of the art [Krazer] used all open source software for this iteration, and sharing his designs means you can build your own for around $200. As always with lasers take extra precautions to protect your eyes! This 200mW setup is no joke, but that doesn’t mean fun and games are out of the question.

3D Printing T-Shirt Designs

August 27, 2017 by Michael Uttmark 28 Comments

Usually, t-shirt designs are screen printed, but that’s so old school. You have to make the silkscreen and then rub paint all over – it’s clearly a technique meant for the past. Well, fear not, as [RCLifeOn] is here to bring us to the future with 3D Printed T-Shirt Designs.

[RCLifeOn] affixes t-shirts to his print build platform and boom: you’ve got 3D printed graphics. He started by using PLA which, while it looked great, wasn’t up to a tussle with a washing machine. However, he quickly moved on to NinjaFlex which fended much better in a wash cycle. While the NinjaFlex washed better, [RCLifeOn] did have some issues getting the NinjaFlex to adhere to the t-shirt. With a little persistence and some settings tweaking, he was able to come out ahead with a durable and aesthetically pleasing result.

Now, 3D printing isn’t going to replace screen printing, but it’s also not going to replace injection molding. What 3D printing lacks in speed and efficiency, it makes up in setup time & cost. In other words, if you need 50 t-shirts of the same design, screen printing is the way to go. But, if you need 50 shirts, each with a different design, you just might want to follow in [RCLifeOn’s] footsteps.

Anyways, we don’t have much on 3D printing t-shirts, but we do have other useful information on 3D printing slinkys and 3D printing project enclosures. And, if you’d rather do it the old-school way, we can show you how to silkscreen all the things.

3D Printer Tool Changer Gives You Access To Lots Of Extruders

August 27, 2017 by Cameron Coward 39 Comments

The benefits of having a 3D printer with multiple extruders are numerous: you can print soluble support material for easy removal, print a combination of flexible and rigid filament, or simply print in different colors. Unfortunately, traditional multi-extruder setups have some serious drawbacks, even aside from the cost.

Usually, the extruders are all mounted next to each other on a single carriage. This increases the mass, which can cause print quality issues like shadowing. It also reduces the printable area, as each extruder needs to be able to reach the entire area. All of this means that the design becomes more and more impractical with each extruder you add, and that’s why it’s uncommon to see more than two extruders on a printer.

Over on Hackaday.io, [rolmie] has come up with a very practical (and affordable) solution to this problem. He has designed a tool changer that gives the printer the ability to switch out hot ends on the fly. The system is very similar to the tool changers we see on CNC machining centers: tools (the hotends) are stored on a rack, and a tool change in the G-code sends the carriage over to the rack to drop off the old hotend and pick up a new one.

The benefit of the design is that both the mass and volume of the carriage are kept to a minimum, while allowing you to use many different hot ends. Each hotend’s settings can be configured individually, and you can even use different models of hotend altogether (maybe one model works better for PLA, while another is better for ABS). The design is still in the prototyping stage and needs some refinement, but it’s a very promising proof of concept that seems like it could be implemented fairly easily into most 3D printer models.

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Casting Metal Directly Into 3D Printed Molds

August 27, 2017 by Brian Benchoff 24 Comments

Casting metal and 3D printing go together like nuts and gum, and there are no shortage techniques that use the two together. Lost PLA casting is common, and sculptors are getting turned on to creating their works in plastic first before sending it off to the foundry. Now the folks at FormLabs have turned the whole ‘casting metal and 3D printer’ thing on its head: they’re printing sacrificial molds to cast pewter.

There are two techniques demonstrated in this tutorial, but the real winner here is printing a complete sacrificial mold for pewter miniatures. While this technique requires a little bit of work including washing, curing, and a bit of post-processing, you would have to do that anyway with anything coming out of a resin printer.

The material of choice for these molds is a high temp resin with a heat deflection temperature of 289 °C. Using a pewter alloy that melts at 260 °C, casting a metal miniature is as simple as pouring molten metal into a mold. Demolding might be a little finicky, but with a small screwdriver used as a chisel, it’s possible to get the cast newly parts out.

We’ve seen pewter casting with PLA, but the quality available from the Form resin printers is truly amazing and produces some great looking miniatures.

DIY Mocha Cooker

August 27, 2017 by Inderpreet Singh 27 Comments

Food-grade 3D printing filament is on the rise and it is nice to have a custom coffee mug in the office to instill a little envy in the locals. [Stefan] took it upon himself to create a Mocha Machine that he would 3D print and test the boundaries of his filament.

[Stefan] used Fusion 360 to replicate the famous Bialetti Moka Express pot in it true octagonal shape. Since the pot brews coffee under pressure, he tested tolerances in Fusion 360 to make sure all the thicknesses were right. While the design was being printed, a steel washer was added to facilitate induction heating since you can’t really put a plastic pot over a flame. The print uses Formfutura Volcano PLA which is annealed for an hour at 110 degrees Celsius.

Below is a video of the whole process and though the material may not be food grade, the project is definitely a step in the right direction. Since the printed parts can withstand temperatures of up to 160 degrees Celsius, projects that involve boiling water or experiments with crystallization can benefit from a custom design.

We really hope to see more projects that use this technique, however, for those looking at their coffee machine right now, take a look at more coffee machine hacks as well as alarm clock hacks to get the coffee brewing in the morning.

Thanks for the tip [Nils Hitze] Continue reading “DIY Mocha Cooker” →

A Functioning 3D Printer For 10€

August 26, 2017 by Jenny List 42 Comments

There was a time when crowdfunding websites were full of 3D printers at impossibly low prices. You knew that it would turn out to be either blatant vaporware or its delivery date would slip into the 2020s, but still there seemed always to be an eager queue ready to sign up. Even though there were promised models for under $200, $150, and then $100, there had to be a lower limit to the prices they were prepared to claim for their products. A $10 printer on Kickstarter for example would have been just a step too far.

There is a project that’s come close to that mark though, even though the magic figure is 10 euros rather than 10 dollars, so just short of 12 dollars at today’s exchange rate. [Michele Lizzit] has built a functioning 3D printer for himself, and claims that magic 10€ build price. How on earth has he done it? The answer lies in extensive use of scrap components, in this case from broken inkjet printers and an image scanner. These provide all the mechanical parts for the printer, leaving him only having to spend his 10€ on some hot end parts and the printer’s electronics. In an unusual move, the frame of the machine appears to come from a set of cardboard biscuit boxes, a master stroke of junk box construction.

The claimed resolution is 33µm, and using the position encoders from the inkjet printers he is able to make it a closed loop device. We salute his ingenuity in building such an impressive printer from so little, and were we ever locked by the bad guys in a room full of IT junk and lacked a handy escape device, we’d wish to be incarcerated with [Michele] any day over [Angus MacGyver] or [Sgt. Bosco BA Baracus].

You can see the printer in action in the video below the break.

Continue reading “A Functioning 3D Printer For 10€” →

Blinking LEDs On The Internet Of Printers

August 25, 2017 by Brian Benchoff 7 Comments

When you ask for recommendations on which 3D printer to buy, damn the cost, the Ultimaker is consistently at the top of the list. There’s a reason for the popularity of this printer — it’s easy to use, extremely high quality, and has an entire freakin’ Linux system running somewhere under the hood. That last bit is opening up a few doors to some interesting hacks, like using a 3D printer as an RGB LED.

The Doodle3D team has been playing around with the Ultimaker API to see if they can make their software work with the Ultimaker printer. The Ultimaker has RGB LEDs, so obviously the simplest proof of concept in futzing around with an API is to blink a few LEDs. The actual code was written in HTML, JavaScript, and Node in just two hours. The author admits it’s ugly, but it works. Can’t go wrong with that.

While this is just a simple test of the Ultimaker API, it’s surprisingly high up on the Google results when you search, ‘Ultimaker API’. That’s a shame, because there’s a lot of power under the hood of this printer. If you have some sort of mod you’d like to throw into the ring, here’s the Hackaday Tip Line.

You can check out the demo video of this hack below.

Continue reading “Blinking LEDs On The Internet Of Printers” →