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3D Printing RC Airplanes That Fly: An Engineer’s Chronicle

January 5, 2015 by 14 Comments

In the past, creating accurate replicas of models and fantasy objects was a task left to the most talented of cosplayers. These props need not be functional, though. [Steve Johnstone] takes replica model-building to the next step. He’s designing and building a model airplane that flies, and he’s documenting every step of the way.

Armed with a variety of 3D printing techniques and years of model-building experience, [Steve] is taking the lid off a number of previously undocumented techniques, many of which are especially relevant to the model-builder equipped with a 3D printer in the workshop.

As he continues his video log, [Steve] takes you through each detail, evaluating the quality of both his tools and techniques. How does a Makerbot, a Formlabs, and a Shapeways print stand up against being used in the target application? [Steve] evaluates a number of his turbine prints with a rigorous variable-controlled test setup.

How can we predict the plane’s center-of-gravity before committing to a physical design? [Steve] discusses related design decisions with an in-depth exploration of his CAD design, modeled down to the battery-pack wires. Though he’s not entirely finished, [Steve’s] work serves as a great chance to “dive into the mind of the engineer,” a rare opportunity when we usually discover a project after it’s been sealed from the outside.

3D printing functional parts with hobbyist-grade printers is still a rare sight, though we’ve seen a few pleasant and surprisingly practical components. With some tips from [Steve], we may complete this video journey with a few techniques that bump us out of the “novelty” realm and into a space where we too can start reliably printing functional parts. We’re looking forward to seeing the maiden voyage.

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3D Printed Lawnmower

Wait, A 3D Printed Lawn Mower?

January 5, 2015 by 80 Comments

Well, we have to admit, we never saw this coming… A 3D printed lawn mower? What? Why? Huh? How? Those were at least a few of the thoughts running through our head when we saw this come in on the tips line.

[Hans Fouche] has a giant 3D printer that takes up most of the space in his garage, and after printing several large vases, a briefcase, bowls, and even a wind turbine blade — he decided to try printing a lawnmower. A freaking lawnmower.

To do so, he reverse engineered his old rusty lawn mower, and redesigned it to be printable. Apart from the steel axles, some fastening hardware, and of course the motor and blade, the entire thing is 3D printed. And it looks like it works pretty good too.

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LED Desk Lamp

One Way To Get Rid Of That Fluorescent Buzzing Sound

January 4, 2015 by 38 Comments

Tired of the persistent hum his fluorescent desk lamp made, [Andres Lorvi] decided he had to fix it. And by fix, we mean get rid of altogether. He liked the lamp though so he decided to convert it to LED — that way he’d save some money on electricity too!

Besides wanting to get rid of the hum, [Andres] had also been reading up on the effect of light temperature at night — bluish light is typically bad for your eyes when you’re trying to go to sleep. So he also took this opportunity to change the color temperature of the light in his room. Unfortunately it wasn’t as simple as just replacing the fluorescent with the LEDs — no, that would be far too easy…

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Automatic 3D Scanning On The Cheap

January 3, 2015 by 24 Comments

After hearing about a few 3D object scanners, [Will] thought one of these tools could find a place in his workshop. The price of these scanners made him reconsider simply buying one, so he just made one out of parts that were sitting around. This was the first version of his 3D scanner. It worked, but there were a few shortcomings. [Will] had to rotate the object manually. That’s a cheap way of doing it, but the method is tedious.

Now [Will] is back for round two. He’s made some improvements, and this time a few bits of electronics automate the process, allowing [Will] to hit a button, walk away, and come back to a scanned object.

Even though [Will] has improved his setup immensely, the theory of how to scan an object remains the same. He’s projecting a straight vertical line on an object, taking a few snapshots with a webcam, and reconstructing the object with computer vision algorithms and Meshlab. The new additions include a BeagleBone Black, a stepper motor and an EasyDriver from Sparkfun, and a turntable.

[Will] wrote two scripts for this project. The first does the mechanical heavy lifting – turning the stepper motor and taking a picture, while the second converts the output from the webcam to a point cloud. From there, the point cloud is sent over to Meshlab, and an object appears on [Will]’s hard drive.

There’s about $80 in hardware invested in this setup, and considering the inspiration for this project was the $800 Makerbot Digitizer, we’re going to call [Will]’s experiments in 3D scanning a success.

3D Printable LED Diffusors

January 2, 2015 by 15 Comments

While you can get an LED matrix in any size or shape, the really cool looking ones that are perfect for low-res displays all have diffusors. When they come from a nameless Chinese factory, these diffusors are thin sheets of plastic set into an extruded plastic frame. Since [Jana] has a 3D printer, she figured a custom diffusor was just a few bits of filament and a SCAD file away.

The basis for this custom LED diffusor was a LoL Shield given to [Jana] by the creator at the recent 31C3 conference. This shield is really only just 126 LEDs, multiplexed and in an Arduino form factor, and that many LEDs were just too bright and indistinct next to each other. The plan for a 3D printed diffusor was hatched.

After taking a few measurements, a pair of OpenSCAD files were whipped up and printed out. Assembly consisted of pressing 126 tiny little white diffusors into a frame, but once everything was attached to the matrix, the results were worth it.

Check out the video below for the before and after, demonstrating what a few bits of plastic can do to a LED matrix.

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Parametric Spherical Speakers Are Not A Moon

January 1, 2015 by 8 Comments

A good speaker enclosure is not just about building a box out of plywood and covering it with carpet, although playing with 1F capacitors is pretty cool. No, for a good speaker enclosure you need the right internal volume, the right size bass port, the right speaker, and it should definitely, certainly, not be a moon.  [Rich] figured out he could do all of this with a 3D printer, resulting in the NOMOON: The NOMOON Orbital Music-Making Opensource, Openscad-generated Nihilator.

This work is a continuation of earlier work that designed parameterized speakers in the shape of Borg cubes. Now [Rich] is on to Borg scout ships,  and this version has everything you would expect for speaker design.

The NOMOON is available on the Thingiverse Customizer with variables for the internal diameter, the volume of the enclosure in liters, wall thickness, speaker hole, bass port, and wire holes. Of course a customized design is also possible with a stock OpenSCAD installation.

[Rich] has printed a few of these not moons and even with a speaker with terrible bass response, he has a pretty good-sounding setup as far as Youtube videos go. You can check that out below.

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3D Printed SMD Tool

December 31, 2014 by 8 Comments

We’ve seen pick and place tools in the form of tweezers, mechanical pencils adapted to aquarium pumps, but never as a 3D printed tool optimized for standard blunt-nose needles in a comfortable, ergonomic shape.

[Zapta] created this 3D printed SMD hand picker to populate a few boards. The tool is mostly 3D printed parts that come together for an airtight enclosure. The needles are the standard eBay affair, with the smallest he could find easily lifting 0402 and 0603 components from their tape reel. There’s also the option to switch over to larger needles for bigger components.

There are files available for two versions of this vacuum picker – one with a hole in the handle for those of us who would rather connect this thing directly to a modified aquarium pump, and one for the geniuses among us who use a foot pedal and pneumatic valve to release the tiny part. Other than the pump, the only a few bits of tubing are required to turn this bit of 3D printed plastic into a useful tool.