Interview With A Printer

November 19, 2014 by Brian Benchoff 21 Comments

The Hackaday European tour continues, this time in Prague with Josef Průša (Google translate), core developer in the RepRap project, feature at all the Maker Faires and cons, and creator of his namesake, the Prusa Mendel and i3 printers.

[Prusa]’s involvement with the RepRap project started with a RepRap Mendel, the second iteration of RepRap hardware, but the first popular and easy to build version. [Jo] found the Mendel rather difficult to build, so he loaded OpenSCAD and started to design his own version of the hardware. This version became the de facto standard RepRap for a few years, with many inspired by and derivative printers making their way to hackerspaces and workshops around the world.

The first Prusa printer, derived from the RepRap Mendel.

A few years ago, [Prusa] was one of the first to make a complete break with the traditional ‘threaded rod and nut’ construction of RepRaps with the introduction of the Prusa i3. This was the first model that had a metal plate as the frame, another feature that would be seen in dozens of other models. It’s not something that was without controversy, either; using a metal plate for the frame doesn’t allow for as much self-replication, something that’s a core value of the RepRap project. That didn’t matter to the community; the Prusa i3 or a similar design is the third most popular printer on 3Dhubs.

The first Prusa printer showing off its Makerbot heritage

What’s the future of the Prusa name? There is an i4 in the works, and I’m pretty sure that’s all I can tell you. Someone already bought the Prusai4 domain, so there may be a name change.

In the interview below, [Prusa] goes over his involvement with the RepRap project, his business, what he considers to be the latest advances in 3D printing for the past year, what the worst things about the 3D printing scene is (it’s Kickstarter), the state of the RepRap project, and thoughts on SLS, DLP, and SLA printing technologies. Video below.

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Printing In Metal With A MIG Welder

November 7, 2014 by Brian Benchoff 73 Comments

Whenever the question of metal 3D printers comes up, someone always chimes in that a MIG welder connected to a normal 3D printer would work great. A bit of research would tell this person that’s already been done, but some confirmation and replication is nice. A few students at TU Delft University strapped a welder to a normal, off-the-shelf 3D printer and made a few simple shapes.

This project builds on the work of [Joshua Pearce] et al. at Michigan Tech where an MIG welder and delta bot was used to lay down rather complex shapes on a metal plate substrate. The team at TU Delft used a cartesian bot – a Prusa i3 – for their replication because of the sheer mass of moving a metal build plate, firebricks, and welder around.

In the first few prints on their machine, the team was able to lay down enough metal to build a vertical wall. It’s not much, and to turn this into a finished part would require some machining, but these are only the beginning steps of what could become a legitimate way of creating metal parts. Video below.

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Making A Speaker With Resin, Magnets, And Wire

November 1, 2014 by Brian Benchoff 23 Comments

A speaker is just about the simplest electronic component possible, just barely more complex than resistors and wire. They’re also highly variable in their properties, either in size, shape, frequency response, and impedance. Obviously, building custom speakers would be of interest to a lot of people, but there aren’t many people out there doing it. [Madaeon] is one of those people. He created a speaker from scratch, using nothing but magnets, wire, and a bit of UV curing resin.

The frame of the speaker contains a magnet, and the coil of wire is carefully attached to the 0.1mm thin speaker cone with a bit of UV curing resin. All the parts are available on Thingiverse, but you will need a UV resin printer with a low layer height to print this thing out.

The speaker was built by [madaeon] as a demonstration of what the printer he built can do. It’s a fairly standard resin-based 3D printer built around a DLP projector. It’s also cheap, and unlike some other cheap resin-based 3D printers, there’s a reasonable likelihood his will ship within the next few months.

Flying Wing Project Uses 3D Printing To Reach New Heights

October 27, 2014 by James Hobson 58 Comments

A team of engineers from the Advanced Manufacturing Research Centre at the University of Sheffield have just put the finishing touches on their 3D printed Flying Wing with electric ducted fan engines — a mini electric jet so to speak.

Earlier this year they had created a completely 3D printed fixed wing UAV, which the new Flying Wing is based off of. Designed specifically for the FDM process, they were able to optimize the design so that all parts could be printed out in 24 hours flat using ABS plastic.

The new design also almost exclusively uses FDM technology — however the wings are molded carbon fibre… using a 3D printed mold of course! The original glider weighed 2kg, and with the upgrades to the design, the Flying Wing weighs 3.5kg, with speed capabilities of around 45mph.

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Electric Bubblegum Board

October 20, 2014 by Marsh 17 Comments

The Mini Maker Faire in Atlanta was packed with exciting builds and devices, but [Andrew’s] Electric Bubblegum Boards stood out from the rest, winning the Editor’s Choice Award. His boards first emerged on Endless Sphere earlier this summer, with the goal of hitting all the usual e-skateboard offerings of speed, range, and weight while dramatically cutting the cost of materials.

At just over 12 pounds, the boards are lightweight and fairly compact, but have enough LiFePO4’s fitted to the bottom to carry a rider 10 miles on a single charge. A Wii Nunchuck controls throttle, cruise control, and a “boost” setting for bursts of speed. The best feature of this e-skateboard, however, is the use of 3D-printed parts. The ABS components not only help facilitate the prototyping process, but also permit a range of customization options. Riders can reprint parts as necessary, or if they want to just change things up.

[Andrew’s] board is nearing the 11th hour over at his Kickstarter page, so swing by to see a production video made for potential backers, or stick around after the break for some quick progress and demo videos.

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Introducing The F*Watch, A Fully Open Electronic Watch

October 17, 2014 by Mathieu Stephan 24 Comments

As one of their colleagues was retiring, several CERN engineers got together after hours during 4 months to develop his gift: a fully open electronic watch. It is called the F*Watch and is packed with sensors: GPS, barometer, compass, accelerometer and light sensor. The microcontroller used is a 32-bit ARM Cortex-M3 SiLabs Giant Gecko which contains 128KB of RAM and 1MB of Flash. In the above picture you’ll notice a 1.28″ 128×128 pixels Sharp Memory LCD but the main board also contains a micro-USB connector for battery charging and connectivity, a micro-SD card slot, a buzzer and a vibration motor.

The watch is powered by a 500mA LiPo battery. All the tools that were used to build it are open source (FreeCAD, KiCad, GCC, openOCD, GDB) and our readers may make one by downloading all the source files located in their repository. After the break is embedded a video showing their adventure.

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3D printed Chivalry Medieval Warfare Mace

3D Printing Models From Computer Games

October 13, 2014 by James Hobson 22 Comments

Wouldn’t it be cool to extract 3D models from your favorite video games and then 3D print them? As it turns out, it’s pretty easy to do!

In the following video tutorial he shows us how to extract the 3D meshes from a video game called Chivalry, Medieval Warfare. The game is based on the unreal engine which makes it super easy to get the files.

Quick note on legality: If you choose to rip 3D models from your video games and print them, make sure you’re just printing them for yourself, not to sell.

To start, you’ll need a few pieces of software to help you out. First up is something called Umodel, which is an Unreal Engine Resource Viewer, which allows you to view and extract files from any game that uses the Unreal Engine. Once you find your model in the game directory, you can open it up in Umodel and save it as a .PSK file. From there you can open .PSK files with another program called Milkshape 3D, and then export in .OBJ file. Finally you can use MeshMixer to import .OBJ files, repair the mesh by removing the extra shells (you can use the cloud NetFabb service to help repair files for 3D printing as well), and then finally save as .STL ready to print.

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