3D Printed Cyclone Dust Separator

April 10, 2014 by James Hobson 17 Comments

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[Nicholas] has been reading Hackaday for a few months now, and after seeing several people’s dust extractor setups, he decided to make his own 3D printed version. And he’s sharing the files with everyone!

He has a small Lobo mill which produces a lot of dust and to clean up he’s been using a small “Shark” brand vacuum cleaner. It’s a powerful little thing, but has little to no capacity which makes it rather frustrating to use. This makes it a perfect candidate for a cyclone upgrade! If you’re not familiar with cyclonic separator it’s a way of removing dust from air using vortex separation — between rotational forces and gravity, this keeps the dust out of your vacuum cleaner and means you never need to change another filter!

Using Autodesk inventor he designed this 4-stage cyclone separator. It’s made for a 1.75″ OD vacuum hose (the Shark standard) but could be easily modified for different vacuums. We’ve seen lots of cyclone separators before, but this 3D printed one certainly makes it easier to fabricate to exacting standards!

Resetting DRM On 3D Printer Filament

April 10, 2014 by Brian Benchoff 94 Comments

The Da Vinci 3D printer is, without a doubt, the future of printing plastic objects at home. It’s small, looks good on a desk, is fairly cheap, and most importantly for printer manufacturers, uses chipped filament cartridges that can’t be refilled.

[Oliver] over at Voltivo was trying to test their new printer filament with a Da Vinci and ran head-on into this problem of chipped filament. Digging around inside the filament cartridge, he found a measly 300 grams of filament and a small PCB with a Microchip 11LC010 EEPROM. This one kilobyte EEPROM contains all the data about what’s in the filament cartridge, including the length of filament remaining.

After dumping the EEPROM with an Arduino and looking at the hex file, [Oliver] discovered the amount of filament remaining was held in a single two-byte value. Resetting this value to 0xFFFF restores the filament counter to its virgin state, allowing him to refill the filament. A good thing, too; the cartridge filament is about twice as expensive as what we would normally buy.

3D Printed Camera Arm Saves $143

April 7, 2014 by James Hobson 29 Comments

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Professional camera equipment is notoriously expensive, so when [Raster’s] LCD camera arm for his RED ONE Digital Cinema Camera broke, he was dismayed to find out a new one would run him back $150! He decide to take matters into his own hands and make this one instead.

The original arm lasted a good 4 years before finally braking — but unfortunately, it’s not very fixable. Luckily, [Raster] has a 3D printer! The beauty with most camera gear is it’s all 1/4-20 nuts and bolts, making DIY accessories very easy to cobble together. He fired up OpenSCAD and started designing various connector blocks for the 1/4-20 hardware to connect to. His first prototype worked but there was lots of room for improvement for the second iteration. He’s continued refining it into a more durable arm seen here. For $7 of material — it’s a pretty slick system!

Between making 3D printed digital camera battery adapters, 3D printed camera mounts for aerial photography, affordable steady-cams, or even a fully 3D printed camera… getting a 3D printer if you’re a photography enthusiast seems to make a lot of sense!

University Attempts To Break 3D Printing World Record

April 5, 2014 by James Hobson 83 Comments

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LeTourneau University attempted to set a 3D printing Guinness World Record yesterday. They had 50 3D printers print the same thing at the same time. Impressive? Kind of, but not really.

LulzBot — our favorite 3D printer company — saw this and thought “that’s cute — we run over 50 printers a day on a normal basis!”. So just for lulz, they decided to film a little counter-record video featuring 109 LulzBot 3D printers running simultaneously.

To be honest, we kinda feel sorry for LeTourneau University — but it looks like LulzBot really takes the cake here. The university has a really cool policy for their engineering students though — all incoming freshmen students are required to build their own 3D printer for school. Whoa! To be honest it is a really cool way to force you to get out of your comfort zone and learn a bit about several different engineering disciplines.

To follow along the discussion and status of the record, a thread is going on over at 3Dprintboard.com. Stick around to see the video of LulzBot’s drool worthy server racks filled with identical printers.

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Turning The Makerbot Into A Tattoo Machine

April 3, 2014 by Brian Benchoff 24 Comments

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ENSCI les Ateliers, the famous design school in Paris, had a “Public Domain Remix” and hackathon recently, with teams splitting up to remix public domain and other free-to-use IP in projects. Most of the teams came up with similar ideas, but one team went above and beyond the call of duty; they turned a 3D printer into a tattoo machine, capable of inking a real, live human test subject.

The build began by plotting a circle with a pen onto a piece of paper. This evolved into printing a tool holder for a tattoo machine graciously provided by an amateur tattoo artist. Tests with “artificial skin” (any one care to hazard a guess at what that is?) were promising, and the team moved on to a human guinea pig.

The biggest problem the team faced is that humans aren’t flat. They tried a few tricks to tighten the skin around the area to be tattooed – metal rings, elastics, and finally the inner tube from a scooter. In the end, the team was able to tattoo a small circle on the forearm of the test subject.

It’s an extremely simple and small tattoo, and scaling this build up to a sleeve would be difficult. A better solution would be to create a point cloud of an arm before going for a much larger tattoo.

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3D Printed Splint Saves Baby’s Life

April 2, 2014 by James Hobson 31 Comments

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Here’s another heartwarming story about how 3D printers are continuing to make a real difference in the medical world. [Garrett] is just a baby whose bronchi collapse when breathing — he’s been on a ventilator for most of his life — Until now.

[Scott Hollister] is a professor of Biomedical Engineering and Mechanical Engineering, as well as being an associate professor of surgery at the University of Michigan. Between him and [Doctor Glen Green], an associate professor of Pediatric Otolaryngology, they have created a bioresorbable device that could save little [Garrett’s] life.

By taking CT scans of [Garrett’s] bronchi and trachea, they were able to create a 3D model and design a “splint” to help support the bronchi from collapsing during normal breathing. If all goes well, within 3 years, the splint will dissolve in his body and he will be able to breath normally for good. The material in question is a biopolymer called polycaprolactone, which they were actually granted emergency clearance from the FDA to use for [Garrett]. They used an EOS SLS based 3D printer.

The surgery was successful, and [Garrett] is now on the road to recovery. Stick around for a few videos showing of the printing process and surgery.

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Dispensing Solder Paste With A 3D Printer

April 2, 2014 by Brian Benchoff 37 Comments

There’s a strange middle ground in PCB production when it comes to making a few boards. Dispensing solder paste onto one board is easy enough with a syringe or toothpick, but when pasting up even a handful of boards, this method gets tiresome. Solder paste stencils speed up the process when you’re doing dozens or hundreds of boards, but making a stencil for just a few boards is a waste. The solution for this strange middle ground is, of course, to retrofit a 3D printer to dispense solder paste.

This project was a collaboration between [Jake] and [hzeller] to transform KiCAD files to G Code for dispensing solder paste directly onto a board. The machine they used was a Type A Machines printer with a solder paste dispenser in place of an extruder. The dispenser is hooked up to the fan output of the controller board, and from the looks of the video, they’re getting pretty good results for something that’s still very experimental.

All the code to turn KiCAD files into G Code are up on [hzeller]’s github. If you’re wondering, the board they’re pasting up is a stepper driver board for the BeagleBone named Bumps.

Videos below.

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