Adding Copper Wire To A 3D Print

May 25, 2014 by Brian Benchoff 24 Comments

Conductive filaments and printing solder are one thing, but what if you could spice up your 3D prints by embedding wire right inside the filament? That’s what [Bas] is doing, paving the way for printable electronics, PCBs, coils, and odd-shaped antenna.

The general idea of [Bas]’ technique of embedding thin copper wire inside a single layer of a print is to lay the wire down in front of the nozzle, effectively turning bare wire into insulated wire in whatever shape you can imagine. The trick, however, is figuring out how to put wire down in front of a nozzle. [Baz] accomplished this with a slew ring turned by a stepper motor connected to a 5th axis on the control board.

There are a few things this prototype doesn’t cover – cutting the wire, connecting the wire to components, fine-tuning, and a host of other things that prevent [Bas]’ machine from building real functional circuits. Despite these limitations, the machine could probably fabricate the secondary for a tesla coil right now, something that’s really annoying to make unless you have a lathe.

Video demo below.

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The Hour Of The 3D Printed Clock Draws Nigh

May 24, 2014 by Adam Fabio 15 Comments

Many have tried, but [Christoph Laimer] has succeeded in designing a working, (relatively) accurate clock nearly completely from 3D printed parts. Every gear, pulley, wheel and hand of [Christoph’s] clock is printed. Only a few screws, axles, a weight, and a string are non-printed. Even the crank to wind the clock is a 3D printed part.

[Christoph] designed his clock in Blender. It took quite a bit of design work to create parts that would work and be printable. Even more work was involved in printing over 100 failed prototype parts.

One might think that [Christoph] is using the latest printers from the likes of Makerbot or Utimaker to achieve this feat. It turns out he’s using a discontinued Rapman 3.2 printer. Further proof that even “older” printers are capable of great things! [Christoph] does run his printer rather slowly. Printing a single gear with 0.125 mm layers and a 0.4 mm nozzle takes him 2 or 3 hours.

Mechanically, the clock is gravity powered with an anchor escapement. Rather than a pendulum, [Christoph] chose to use a balance wheel and hairspring assembly to govern the escapement. Even the spring is printed from standard PLA. The weight is suspended from a pulley block. The clock isn’t particularly efficient. 70cm of height will run the clock for only 2 hours.

[Christoph’s] clock has proven to be accurate to within 1/4 second per hour. He hasn’t provided temperature stability data – but being PLA, we’d suggest not getting it too hot!

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MakerBot Files Patents, Internet Goes Crazy

May 24, 2014 by Brian Benchoff 100 Comments

In the past month, a few patent applications from MakerBot were published, and like everything tangentially related to the prodigal son of the 3D printer world, the Internet arose in a clamor that would be comparable only to news that grumpy cat has died. That’s just an analogy, by the way. Grumpy cat is fine.

The first patent, titled, Three-dimensional printer with force detection was filed on October 29th, 2013. It describes a 3D printer with a sensor coupled to the hot end able to sense a contact force between the nozzle and build plate. It’s a rather clever idea that will allow any 3D printer to perform software calibration of the build plate, ensuring everything is printed on a nice, level surface. Interestingly, [Steve Graber] posted an extremely similar design of a bed leveling probe on October 6th, 2013. In [Steve]’s video, you can see his bed level probe doing just about everything the MakerBot patent claims, all while being uploaded to YouTube before the patent application.

When it rains it pours, and the Quick-release extruder patent application, filed on October 28, 2013, bears this out. It claims an extruder that includes, “a bistable lever including a mechanical linkage to the bearing, the bearing engaged with the drive gear when the bistable lever is in a first position and the bearing disengaged from the drive gear when the bistable lever is in a second position.” Simple enough, a lever with two positions, where one presses a bearing against a drive gear, and the other position disengages the bearing from a drive gear. Here’s something that was published on Thingiverse in 2011 that does the same thing. Hugely famous RepRap contributor [whosawhatsis] has weighed in on this as well.

It is important to note that these are patent applications. Nothing has been patented yet. The US Patent and Trademark Office does seem to have a lot of rubber stamps these days, so what is the average Internet denizen to do? Here are easy to follow, step-by-step instructions on how to notify the USPTO of prior art. Remember, just because prior art does not completely invalidate a patent application’s claims doesn’t mean you shouldn’t send it in. It is a patent examiner’s job to review the prior art.

So there you go. MakerBot applies for patents, people complain, but not to the USPTO. Highly relevant video and transcription below.

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CastAR And Holographic Print Preview For 3D Printers!

May 23, 2014 by James Hobson 18 Comments

CastAR and 3D printing

Google glasses this, Oculus rift that, CastAR… With all these new vision devices coming out, the world of augmented reality is fast becoming, well, a reality!

Here’s a really cool concept [Ryan Smith] came up for 3D printing. Using [Jeri Ellsworth’s] CastAR, [Ryan Smith] has created a really cool technical illusion to demonstrate visual prototyping on his Makerbot. Using a laser cutter he’s perforated the front plastic panel of the Makerbot, which allows a semi-transparent overlay that when you use the CastAR’s projector it gives you a holographic visual effect.

The glasses track the reference object (in this case, the gear) and then project interfacing gears in an animation over-top of the existing part. [Ryan] sees this as the next step in 3D printing for artists and makers because it can help give you a 3D preview of your part, for example if you’re not fully sure what scale you want it to print at, you could actually put a mating object, or your hand, behind the screen and visually see the interface!
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Making Manual Lens Flares With A Few Simple Parts

May 13, 2014 by James Hobson 16 Comments

DIY Lens Flare

If you’re an aspiring film maker hoping to be the next [J.J. Abram] with a mild (severe?) obsession with lens flares, then this Instructable is for you!

Modern camera lenses are designed to prevent lens flare, but sometimes, just sometimes, you want a cool lighting flare in your video. Of course you could add them in post production, but that’s kind of cheating, and if you don’t have expensive video editing software, not very easy to do either.

Now you could just throw a super bright LED flashlight on set and hope for the best, but you’ll never get that cool Star Wars or Star Trek blinding purple line… unless you add something on your camera to help scatter the light! [Jana Marie] has figured out just how to do that. Continue reading “Making Manual Lens Flares With A Few Simple Parts” →

Unbricking The Da Vinci And Installing Custom Firmware

May 11, 2014 by Brian Benchoff 67 Comments

We’ve seen a lot of projects based around the Da Vinci 3D printer, all deserved, because the Da Vinci is honestly a terrible 3D printer; it has chipped and DRM filament cartridges, a terrible software interface, and completely closed firmware. The first two shortcomings have already been taken care of, and now the door is open for open source firmware on the Da Vinci printer.

[Jason] bricked his Da Vinci when upgrading the firmware, and like any enterprising tinkerer opened up the enclosure and took a look at the electronics board. He found an ATSAM3X8E, a very capable ARM Cortex-M3 microcontroller. This is the same processor in the Arduino Due, making it possible to write code for the Due and upload it to the Da Vinci controller.

After installing Atmel Studio 6, he noticed the printer controller showed up in the device manager, making it a snap to upload updated firmware, unbricking his printer.

With the ability to upload firmware, the problem quickly becomes writing new open source firmware, or at least porting existing firmwares; there are a few people across the internet trying to reverse engineer the board schematic from the PCB. Once that’s done, it should be a trivial matter to make the Da Vinci an open device, and teaching a lesson to every company that thinks they can sell a closed device in what is ultimately an open ecosystem.

Blobless Printing With Velocity Extrusion

May 10, 2014 by Brian Benchoff 29 Comments

velocity

The current crop of 3D printers are technically four-axis machines, with three axes of movement and a fourth for the position of the filament. [Bas] had an entirely different idea – why not link the speed of the extruder to the speed of the nozzle? It turns out this technique gives you more ‘plasticy-looking’ prints and a vast reduction in blobbiness.

[Baz] has been working with LinuxCNC, a BeagleBone Black and the BeBoPr-Bridge cape, and there’s been a lot of development with that system in turning many straight lines into one smooth arc. This led him to adjusting the flow rate of a nozzle while the printer is running, but this is difficult if the extrusion is controlled by position as in a traditional printer setup. A new configuration was in order.

What [Baz] ended up with is a config that calculated the speed of the extruder based on the speed the nozzle is moving over the print surface. This gave him the ability to add live nozzle pressure adjustment, and as a result, a near complete disappearance of the little blobs that appear at the start of each layer.

For a well calibrated machine, it’s only a small difference between the ‘normal’ and ‘velocity’ methods of controlling an extrusion rate. It’s a noticeable difference, though, and one that vastly improves the visual quality of a print.