Super Detailed 3d Scans With Photogrammetry

February 3, 2016 by Gerrit Coetzee 25 Comments

Photogrammetry is a real word, and [shapespeare] built himself a nice setup to take high-res 3d scans using it. A good set of images for photogrammetry are: in sharp focus, well lit, precisely indexed, and have a uniform background. The background was handled by a 3d printed stand and some copier paper. To get even lighting he used four adjustable LED lamps from Ikea.

In order to precisely index the object, he built an indexing set-up with an Arduino and a stepper motor (housed in the, self proclaimed, most elegant of 3d printed enclosures). The Arduino rotates the platform a measured increment, and then using [Sebastian Setz]’s very neat IR camera control library, snaps a photo. This process repeats until multiple photos of the object have been taken.

Once the photos have been taken, they need to be run through a photogrammetry processor. [shapespeare] uses Agisoft Photoscan, but says Autodesk Memento and 123d Catch do pretty well too. After all this work it appears that [shapespeare] used his new powers to 3d print a giant decking screw. Cool.

Fully Printed CNC On An IKEA Table

February 2, 2016 by Gerrit Coetzee 15 Comments

It seems that many 3D printer owners just aren’t getting the same buzz they used to off their 3D printers, and are taking steps to procure heavier machines. And making them in their home laboratories with, you guessed it, their 3D printers.

Following the pattern, [Michael Reitter], designed a 3D printable CNC around a IKEA MALM table. In order to span the length of the table for his X axis, he came up with a very cool looking truss assembly. The linear rails rest on top of the truss, and a carriage with the Z axis rides on the assembly. The truss has enough space in the center of it to neatly house some of the wiring. The Y-xis mounts on the side of the table.

Overall the mechanical design looks pretty solid for what it is, with all the rails taking their moments in the right orientation. We also like the work-piece hold downs that slide along the edge of the table. It even has a vacuum attachment that comes in right at the milling bit.

We’re not certain how much plastic this build takes, but it looks to be a lot. Monetarily, it will probably weigh in at a bit more than some other options. As many in the 3D printing world are discovering, sometimes there’s no reason not to leverage more mature industrial processes for lower cost large gains in accuracy and strength. Though, it’s pretty clear that one of the design goals of this project was to see how much one can get away with just a 3D printer, and we certainly can’t deny the appealing aesthetic of this CNC.

Video of it in action after the break.

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Making Parametric Models In Fusion 360

February 2, 2016 by Gerrit Coetzee 51 Comments

We all know and love OpenSCAD for its sweet sweet parametrical goodness. However, it’s possible to get some of that same goodness out of Fusion 360. To do this we will be making a mathematical model of our object and then we’ll change variables to get different geometry. It’s simpler than it sounds.

Even if you don’t use Fusion 360 it’s good to have an idea of how different design tools work. This is web-based 3D Modeling software produced by Autodesk. One of the nice features is that it lets me share my models with others. I’ll do that in just a minute as I walk you through modeling a simple object. Another way to describe what we’re going to learn is: How to think when modeling in Fusion 360.

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New Research Sheds Light On 3D Printing Fumes

February 1, 2016 by Elliot Williams 28 Comments

A few years back, there were some studies on the chemical and particle emissions coming out of the hotends of 3D printers. Although they galvanized a lot of people in the community, the science wasn’t entirely conclusive — one paper made it sound like you needed a hazmat suit for 3D printing, and the other suggested that cooking a meal in a kitchen was worse for you. That’s because they were measuring different things.

This new research paper on the emissions of 3D printers covers all the bases. They examined a variety of different materials printed in different printers. They also measured both chemical emissions and Ultrafine Particles (UFP) which can be hazardous even when the material itself is not.

We read the paper (PDF) so that you don’t have to. Here’s our takeaways:

There was no significant variation across brands of 3D printers. (Duh?)
ABS and similar materials outgas styrene at levels you should probably be worrying about if you’re running your printer for a few hours a day in an unventilated office.
PLA emitted significantly less overall, and most of it was a non-hazardous chemical, lactide. PLA doesn’t look like a problem.
All of the materials resulted in increased UFP exposure. These levels are above normal household background levels, but lower than certain “microclimates” which (if you follow the references) include principals’ offices with carpet, automobiles, restaurants, and rooms with burning candles or running hair dryers. In short, the UFP exposure doesn’t look like it’s going to be a big deal unless you’re sitting right next to the printer and running it continually.

So what would we do? It now looks like it’s prudent to print ABS only in a well-ventilated room. Or enclose the printer in a box and vent whatever you can outside — which can also help prevent breezes cooling the piece down unevenly and adding to ABS’s warping problems. Or just stick to PLA. It looks essentially harmless.

Thanks [Jim Scheitel] for the tip!

Tribed 3D Printer Configuration Doesn’t Ever Need To Be Leveled

January 31, 2016 by Gerrit Coetzee 31 Comments

[Jeremie Francois] has been thinking about ways to improve tool height adjustment and bed leveling in his 3D printer for a long time. His dream was to never ever think about Z height again. A dream that’s shared by many. These days, a lot of 3D printers have a mechanism for auto leveling in the software of the 3D printer. This works pretty well, but for various mechanical reasons, it’s better to have the bed itself be level.

[Jeremie]’s approach is pretty clever. Since you can define any plane mathematically with three points, he has three Z-axis lead screws. This lets him tilt the bed at any angle he likes. Once he had the mechanics in place, he added some force sensitive resistors, an Arduino, and wrote an extension for the popular Marlin firmware. That’s when the problems started.

It turns out that solidly mounting the bed to the resistors transmitted way too many vibrations. The solution was a layer of neoprene rubber. The neoprene also acts as a cushion, so the nozzle won’t break the glass bed during the leveling procedure.

The video after the break is a bit wavy, due to YouTube’s terrible auto-stabilizing software, but if you watch closely, you can see the system at work.

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This Is My 3D Printed Brain!

January 30, 2016 by Rud Merriam 25 Comments

This hack is a strange mixture of awesome and ghoulish. [Andrew Sink] created a 3D printed version of his brain. He received a CD from an MRI session that contained the data obtained by the scan. Not knowing what to do with it he created a model of his brain.

Out of a number of images, some missing various parts of his head, he selected the one that was most complete. This image he brought into OisriX, a Mac program for handling DICOM files. He worked on the image for an hour dissecting away his own eyes, skull, and skin. An STL file containing his brain was brought over to NetFabb to see how it looked. There was still more dissection needed so [Andrew] turned to Blender. More bits and pieces of his skull’s anatomy were dissected to pare it down to just the brain. But there were some lesions at the base of the brain that needed to be filled. With the help of [Cindy Raggio] these were filled in to complete the 3D image.

The usual steps sent it to the 3D printer to be produced at 0.2 mm resolution. It only took 49 hours to print at full-size. This brain was printed for fun, but we’ve seen other 3D printed brain hacks which were used to save lives. How many people do you know that have a spare brain sitting around?

Adorable Quadruped Robot Hops And Walks

January 29, 2016 by Dan Maloney 16 Comments

The ESP8266 is finding its way into all sorts of projects these days. It’s a capable little device, to be sure, but we’d have to say that finding it running a quadruped robot that can hop and run was a little unexpected. And to have it show up in such an adorable design was pretty cool too.

From the looks of [Javier Isabel]’s build log, he put a lot of thought into [Kame]. All the body parts and linkages are 3D printed from PLA, with the nice touch of adding a contrasting color. The legs are powered by eight high-speed Turnigy servos, and good quality bearings are used in the linkages. A NodeMCU runs the show with custom oscillator algorithms that control the various gaits, including the hopping motion. The BOM even lists “Adhesive 12mm diameter eyes” – perhaps that’s some sort of slang for the more technically correct “googly eyes.”

Built primarily as a test platform for studying different gaits, there doesn’t seem to be much in the way of sensors in [Kame]’s current incarnation. But with an ESP8266 under the hood, the possibilities for autonomous operation are good. We look forward to seeing where this project goes next. And we kid about the cuteness factor, but never doubt the power of an attractive design to get the creative juices flowing.

We’ve covered a lot of quadruped robots before, and a lot of them seem to trend toward the cute end of the spectrum. Check out this baby-quad that’s learning to walk or this quad that thinks it’s a puppy.

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