Automated Bed Leveling For 3D Printers Is Now Solved

April 15, 2014 by Brian Benchoff 39 Comments

The latest and greatest feature for 3D printers – besides being closed source, having no meaningful technical specs, and being on track towards pulling in $10 Million on a Kickstarter – is automated bed leveling. This amazingly useful feature makes sure your prints have proper adhesion to the bed, reduce print errors, and put even inexpensive printers into the realm of extremely expensive professional machines. Automated bed leveling has been extremely hard to implement in the past, but now [Scottbee] has it figured out with a working prototype on his Makerbot Replicator 2X.

Earlier attempts at automated bed leveling used some sort of probe on the tool head to measure the build plate, calculate its flatness and orientation in space, and compensate for any tilt in software. [Scottbee]’s solution to the problem took a different tack: instead of trying to compensate for any odd orientation of the build surface in software, he’s simply making the bed level with a series of springs and cam locks.

[Scottbee]’s device levitates the build plate on three springs, and replaces the jack screws with three “gimballing pins” and pin locks. With the pin locks disengaged, the bed plate is pressed down with the printer’s nozzle. By moving the extruder across the build plate and locking the pins in place one by one, [Scottbee]’s device defines the plane of the build plate along three points. This makes the build platform parallel to the extruder nozzle, and also has a nice benefit of setting the distance from the build platform to the nozzle precisely with incredible repeatability.

The mechanics of locking the three gimballing pins in place only requires a single DC gear motor, driven by an extra fan output on the Makerbot’s electronics. It’s simple, and with a bit of rework, it looks like most of the device could also be 3D printed.

An awful lot of RepRaps and 3D printers out there already use three points to attach the build plate to a frame. With a little bit of effort, this same technique could be ported and made a bit more generic than the Makerbot-based build seen above. It’s amazingly simple, and we can’t wait to see this applied to a normal RepRap.

Thanks [Josh] for the tip.

Printing In Three Dimensions, For Real This Time

April 13, 2014 by Brian Benchoff 37 Comments

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3D printers don’t continuously print in three dimensions – they print one layer, then another, then another. This is true for every single 3D printing technology, but now Topolabs has a very interesting technique that changes that. They’re printing in three dimensions by moving in the Z axis while also printing in the X and Y axes.

The basic idea behind Topolabs’ software is to print a support block, then print an object right on top of the support. The support block can be curved and convex, and the finished product follows the contours of the solid support block. Unlike ‘printing with supports’, the printer extrudes along the X, Y, and Z axes, which should make the finished product much, much stronger.

There are a few drawbacks to the technique – a release agent must be applied to the top of the support block. In the video below, Topolabs is using Kapton, but hair spray or glue sticks will also work. There’s also a limit to how steep an incline a printer can print, determined by the size of the extruder nozzle. Lastly, this technique would be much better suited for a delta-style bot, but the team is getting very good results with a normal Cartesian bot.

You can see a few videos of the Topolabs printing technique below.

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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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