Hackers, Patents, And 3D Printing

November 16, 2024 by Elliot Williams 34 Comments

Last week, we ran a post about a slightly controversial video that claimed that a particular 3D-printing slicing strategy was tied up by a patent troll. We’re absolutely not lawyers here at Hackaday, but we’ve been in the amateur 3D printing revolution since the very beginning, and surprisingly patents have played a role all along.

Modern fused-deposition modelling (FDM) 3D printing began with Stratasys’ patent US5121329A, “Apparatus and method for creating three-dimensional objects”, and the machines they manufactured and sold based on the technology. Go read the patent, it’s an absolute beauty and has 44 different claims that cover just about everything in FDM printing. This was the watershed invention, and today, everything claimed in the patent is free.

Stratasys’ patent on the fundamental FDM method kept anyone else from commercializing it until the patent expired in 2009. Not coincidentally, the first available home-gamer 3D printer, the Makerbot Cupcake, also went on sale in 2009.

The Stratasys machines were also one of the big inspirations for Adrian Bowyer to start the RepRap project, the open-source movement that basically lead to us all having cheap and cheerful 3D printers today, and he didn’t let the patent stop him from innovating before it lapsed. Indeed, the documentation for the RepRap Darwin dates back to 2007. Zach [Hoeken] Smith delivered our hackerspace the acrylic parts to make one just around that time, and we had it running a year or two before the Cupcake came out of the company that he, Bre, and Adam shortly thereafter founded.

The story of hackers and 3D printers is longer than the commercial version of the same story would imply, and a lot of important innovations have come out of our community since then too. For instance, have a look at Stratasys’ patent on heated bed technology. At first read, it seems to cover removable heated beds, but have a look at the cutout at the end of claim 1: “wherein the polymer coating is not a polymer tape”. This cutout is presumably in response to the at-the-time common practice of buying Kapton, PEI, or PET tape and applying that to removable heated bed surfaces. I know I was doing that in 2012, because I read about it on IRC or something, long before the Stratasys patent was filed in 2014. They could only get a patent for sprayed-on coatings.

As [Helge] points out, it’s also easily verifiable that the current patent on “brick layers” that we’re worrying about, filed in 2020, comes later than this feature request to Prusa Slicer that covers essentially the same thing in 2019. We assume that the patent examiner simply missed that obvious prior art – they are human after all. But I certainly wouldn’t hesitate to implement this feature given the documented timing.

I would even be so bold as to say that most of the post-2010 innovation in 3D printing has been made by hobbyists. While the RepRap movement was certainly inspired by Stratasys’ invention in the beginning, our community is where the innovation is happening now, and maybe even more starkly on the software side of things than the hardware. Either way, as long as you’re just doing it for fun, let the suits worry about the patents. Hackers gotta hack.

You Wouldn’t Download A Chair…But You Could

November 12, 2024 by Lewin Day 16 Comments

[Morley Kert] had a problem. He’s a big fan of the lovely Fortune Chair from Heller Furniture. Only, he didn’t want to pay $1,175 for a real one. The solution? He printed his own instead!

The basic concept is simple. Capture or recreate the geometry of the fancy expensive designer chair, and then print it out on a 3D printer. That would be easy, except for scale. Chairs have to be both big enough to seat humans, and strong enough to carry their weight. For the average 3D printer owner, meeting the big requirement is difficult, since most printers are quite small compared to chairs.

[Morley] gets around this in the typical fashion—he prints the chair in multiple segments. Indeed, we’ve seen [Morley] tackle a similar project before, too. Only, last time, he had the benefit of a print farm and some easily-accessible geometry for the target object. This time, he’s working very much more from scratch, and chose to print everything at home. That made things quite a bit harder.

Scaling up is never as easy at it seems at first!

Continue reading “You Wouldn’t Download A Chair…But You Could” →

Excerpt from 1995 Stratasys patent, showing the drawings of FDM layers, including brick layers.

Brick Layers: The Promise Of Stronger 3D Prints And Why We Cannot Have Nice Things

November 9, 2024 by Maya Posch 87 Comments

It is a fact of life that 3D printed parts from an FDM (fused deposition modeling) printer have weaknesses where the layers join. Some of this is due to voids and imperfect layer bonding, but you can — as [Geek Detour] shows us — work around some of this. In particular, it is possible to borrow techniques from brick laying to create a pattern of alternating blocks. You can check out the video below.

The idea of ‘brick layers’ with FDM prints was brought to the forefront earlier this year by [Stefan] of CNC Kitchen. Seven months after that video you still can’t find the option for these layers in any popular slicers. Why? Because of a 2020 patent filed for this technique by a 3D printing company which offers this feature in its own slicer. But is this patent even valid?

It’s no surprise that prior art already exists in the form of a 1995 Stratasys patent. The above image shows an excerpt from the 1995 Stratasys patent, covering the drawings of FDM layers, including brick layers. This covered all such ways of printing, but the patent expired in 2016. In 2019, a PrusaSlicer ticket was opened, requesting this feature. So what happened? A second patent filed in 2020 assigned to Addman Intermediate Holdings: US11331848B2.

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All Aboard The Good Ship Benchy

November 9, 2024 by Jenny List 26 Comments

We’ll go out on a limb here and say that a large portion of Hackaday readers are also boat-builders. That’s a bold statement, but as the term applies to anyone who has built a boat, we’d argue that it encompasses anyone who’s run off a Benchy, the popular 3D printer test model. Among all you newfound mariners, certainly a significant number must have looked at their Benchy and wondered what a full-sized one would be like. Those daydreams of being captain of your ship may not have been realized, but [Dr. D-Flo] has made them a reality for himself with what he claims is the world’s largest Benchy. It floats, and carries him down the waterways of Tennessee in style!

The video below is long but has all the details. The three sections of the boat were printed in PETG on a printer with a one cubic meter build volume, and a few liberties had to be taken with the design to ensure it can be used as a real boat. The infill gaps are filled with expanding foam to provide extra buoyancy, and an aluminium plate is attached to the bottom for strength. The keel meanwhile is a 3D printed sectional mold filled with concrete. The cabin is printed in PETG again, and with the addition of controls and a solar powered trolling motor, the vessel is ready to go. Let’s face it, we all want a try!

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Fuzzy Skin Finish For 3D Prints, Now On Top Layers

November 8, 2024 by Donald Papp 10 Comments

[TenTech]’s Fuzzyficator brings fuzzy skin — a textured finish normally limited to sides of 3D prints — to the top layer with the help of some non-planar printing, no hardware modifications required. You can watch it in action in the video below, which also includes details on how to integrate this functionality into your favorite slicer software.

Little z-axis hops while laying down the top layer creates a fuzzy skin texture.

Fuzzyficator essentially works by moving the print nozzle up and down while laying down a top layer, resulting in a textured finish that does a decent job of matching the fuzzy skin texture one can put on sides of a print. Instead of making small lateral movements while printing outside perimeters, the nozzle does little z-axis hops while printing the top.

Handily, Fuzzyficator works by being called as a post-processing script by the slicer (at this writing, PrusaSlicer, Orca Slicer, and Bambu Studio are tested) which also very conveniently reads the current slicer settings for fuzzy skin, in order to match them.

Non-planar 3D printing opens new doors but we haven’t seen it work like this before. There are a variety of ways to experiment with non-planar printing for those who like to tinker with their printers. But there’s work to be done that doesn’t involve hardware, too. Non-planar printing also requires new ways of thinking about slicing.

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White pieces on a teal and white chess board. The line of pawns shows three segmented queens in the foreground, one piece being pressed by a man's hand from above in a state between queen and pawn, and the remainder of the pawns in the background in the pawn state.

Transforming Pawn Changes The Game

November 2, 2024 by Navarre Bartz 14 Comments

3D printing has allowed the hobbyist to turn out all sorts of interesting chess sets with either intricate details or things that are too specialized to warrant a full scale injection molded production run. Now, the magic of 3D printing has allowed [Works By Design] to change the game by making pawns that can automatically transform themselves into queens.

Inspired by a CGI transforming chess piece designed by [Polyfjord], [Works By Design] wanted to make a pawn that could transform itself exist in the real world. What started as a chonky setup with multiple springs and a manually-actuated mechanism eventually was whittled down to a single spring, some pins, and four magnets as vitamins for the 3D printed piece.

We always love getting a peek into the trial-and-error process of a project, especially for something with such a slick-looking final product. Paired with a special chess board with steel in the ends, the magnets in the base activate the transformation sequence when they reach the opposite end.

After you print your own, how about playing chess against the printer? We’d love to see a version machined from metal too.

Thanks to [DjBiohazard] on Discord for the tip!

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A Neat Trick To 3D Print With Fewer Warping Issues

November 1, 2024 by Lewin Day 25 Comments

Warping! It messes up your 3D printed parts, turning them into a useless, dimensionally-inaccurate mess. You can design your parts around it, or try and improve your printer in various ways. Or, you can check out some of the neat tricks [Jan] has to tackle it.

The basic concept is a particularly valuable one. [Jan] notes that ABS and PLA are relatively compatible. In turn, he found that printing ABS parts on top of a thin layer of PLA has proven a great way to improve bed adhesion and reduce warping. He’s extended this technique further to other material combinations, too. The trick is to find two materials that adhere well to each other, where one is better at adhering to typical print beds. Thus, one can be used to help stick the other to the print bed. [Jan] also explains how to implement these techniques with custom G-Code and manual filament changes.

We’ve been discussing the issue of warping prints quite often of late. It’s a common problem we all face at one time or another! Video after the break.

Continue reading “A Neat Trick To 3D Print With Fewer Warping Issues” →