3d Printer hacks

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Yet Another Awesome Working Prototype Of A PipBoy 3000

December 2, 2014 by 10 Comments

When we’re not busy writing up features on Hack a Day, some of the writers here have some pretty impressive projects on the go. One of our own, [Will Sweatman], just put the finishing touches on this amazing (and functional!) Pipboy 3000!

The funny thing is, [Will] here isn’t actually a very big gamer. In fact, he hasn’t even played Fallout. But when a friend queried his ability to build this so called “PipBoy 3000”, [Will] was intrigued.

His research lead him full circle, right back to here at Hack a Day. We’ve covered several PipBoy builds over the years, and [Will] fell in love with [Dragonator’s] 3D printed version — it was the perfect place to start. You see, [Dragonator] shared all the 3D models on his personal site!

Now this is where it starts to get cool. [Will] is using a 4D systems 4.3″ touch display, which doubles as the microprocessor — in fact, he didn’t even have to write a single line of code to program in it! The hardware can be programmed using the free Workshop 4 IDE, which allows him to use a visual editor to program the device. Watching a YouTube video on the Fallout 3 PipBoy, he was able to recreate all the menus with intricate detail to load onto the device. It even has GPIO which allow him to use buttons to navigate the menus (in addition to the touch screen stylus).

Continue reading “Yet Another Awesome Working Prototype Of A PipBoy 3000” →

3D Printing Lock Picks

December 1, 2014 by 24 Comments

Over at the 23B hackerspace in Fullerton, CA, [Dano] had an interesting idea. He took a zip tie, and trimmed it to have the same profile of a lock pick. It worked. Not well, mind you, but it worked. After a few uses, the pick disintegrated, but still the concept of picks you can take through a TSA checkpoint was proven.

A few days after this demonstration, [C] realized he had a very fancy Objet 3D printer at work, and thought printing some pics out would be an admirable goal. After taking an image of some picks through the autotracer in Solidworks, [C] had an STL that could be printed on a fancy, high-end 3D printer. The printer ultimately used for these picks was a Objet 30 Pro, with .001″ layer thickness and 600dpi resolution. After receiving the picks, [C] dug out an old lock and went to town. The lock quickly yielded to the pick, and once again the concept of plastic lock picks was proven.

Although the picks worked, there were a few problems: only half the picks were sized appropriately to fit inside a lock. Two picks also broke within 15 minutes, something that won’t happen with traditional metal picks.

Still, once the models are figured out, it’s easy to reproduce them time and time again. A perfect lock pick design is then trivial, and making an injection mold becomes possible. They might still break, but they’ll be far easier to manufacture and simple to replace.

3D Printing Atomic Force Microscopy

December 1, 2014 by 15 Comments

[Andres] is working with an Atomic Force Microscope, a device that drags a small needle across a surface to produce an image with incredible resolution. The AFM can produce native .STL files, and when you have that ability, what’s the obvious next step? That’s right. printing atomic force microscope images.

The AFM image above is of a hydrogel, a network of polymers that’s mostly water, but has a huge number of crosslinked polymers. After grabbing the image of a hydrogel from an Agilent 5100 AFM, [Andres] exported the STL, imported it into Blender, and upscaled it and turned it into a printable object.

If you’d like to try out this build but don’t have access to an atomic force microscope, never fear: you can build one for about $1000 from a few pieces of metal, an old CD burner, and a dozen or so consumable AFM probes. Actually, the probes are going to be what sets you back the most, so just do what they did in olden times – smash diamonds together and look through the broken pieces for a tip that’s sufficiently sharp.

3D Printing Without Support

November 30, 2014 by 12 Comments

3D printing is getting better every year, a tale told by dozens of Makerbot Cupcakes nailed to the wall in hackerspaces the world over. What was once thought impossible – insane bridging, high levels of repeatability, and extremely well-tuned machines – are now the norm. We’re still printing with supports, and until powder printers make it to garages, we’ll be stuck with that. There’s more than one way to skin a cat, though. It is possible to print complex 3D objects without supports. How? With pre-printed supports, of course.

[Markus] wanted to print the latest comet we’ve landed on, 67P/Churyumov–Gerasimenko. This is a difficult model for any 3D printer: there are two oversized lobes connected by a thin strand of comet. There isn’t a flat space, either, and cutting the model in half and gluing the two printed sides together is certainly not cool enough.

To print this plastic comet without supports, [Markus] first created a mold – a cube with the model of the comet subtracted with a boolean operation. If there’s one problem [Markus] ran into its that no host software will allow you to print an object over the previous print. That would be a nice addition to Slic3r or Repetier Host, and shouldn’t be that hard to implement.

Locking A Beer With A 3D Printer

November 30, 2014 by 54 Comments

Have a nice, refreshing IPA sitting in the fridge along with a ton of other beers that have ‘Light’ or ‘Ice’ in their name? Obviously one variety is for guests and the other is for hosts, but how do you make sure the drunkards at your house tell the difference? A beer bottle lock, of course.

Because all beer bottles are pretty much a standard size, [Jon-A-Tron] was able to create a small 3D printed device that fit over the bottle cap. The two pieces are held together with a 4-40 hex screw, and the actual lock comes from a six-pack of luggage padlocks found at the hardware store.

It’s a great device to keep the slackers away from the good stuff, and also adds a neat challenge to anyone that’s cool enough to know basic lock picking. Of course, anyone with a TSA master key can also open the beer lock, but if you’re hosting a party with guest who frequently carry master keys around with them, you’re probably having too good of a time to care.

A UV Lightbox For Curing Prints

November 24, 2014 by 3 Comments

With resin printers slowly making their way to hackerspaces and garages the world over, there is a growing need for a place to cure these UV resin prints. No, they don’t come out of the machine fully cured, they come out fully solid. And no, we’re not just leaving them in the sun, because that’s not how we do things around here.

[Christopher] whipped up a post-cure lightbox meant to sit underneath his Form 1 printer. It’s made of 1/2″ MDF, with adjustable feet (something the Form 1 lacks), a safety switch to keep the lights off when the door is open, and a motor to rotate the parts around the enclosure.

The light source for this lightbox is 10 meters of ultraviolet LED strips. The LEDs shine somewhere between 395-405nm, the same wavelength as the laser diode found in the Form 1 printer. Other than a bit of wiring for the LEDs, the only complicated part of the build was the motor; [Christopher] bought a 2rpm motor but was sent a 36rpm motor. The vendor was out of 2rpm motors, so a PWM controller was added.

It’s a beautiful build that shows off [Christopher]’s ability to work with MDF. It also looks great sitting underneath his printer, and all his parts are rock solid now.

Custom Filaments With A Filastruder

November 24, 2014 by 12 Comments

A while ago, when 3D printing was the new hotness, a few people looked around and said, ‘our printers are open source, why can’t we just build the machines that make our 3D printing filament?’ There was a $40,000 prize for the first person to build an open source filament extruder, resulting in a few filament fabrication machines being released into the wild. [Rupin] over in the Mumbi hackerspace has one of these filament extruders – a Filastruder – and decided to take a look at what it could do.

The experimentations began with a few kilograms of ABS pellets he found at the market, with bags of red, blue, green, and white masterbatch pellets showing up at the Hackerspace. Experimenting with these pellets, [Rupin] was able to create some very nice looking filament that printed well and changed color over the course of a print.

There were a limitations of the process, though: the filastruder has a long melt zone, so colors will invariably mix. If you’re thinking about doing a red to blue transition with filament created on a Filastruder, you’ll end up with a filament with a little bit of red, a little bit of blue, and a lot of a weird purple color. The time to create this filament is also incredibly long; over the course of two days, [Rupin] was able to make about half a kilo of filament.

Still, the results look fantastic, and now that [Rupin] has a source for masterbatch and ABS pellets, he’s able to have a steady supply of custom color filament at the hackerspace.