Let The 3d Printing Patent Wars Begin!

November 21, 2012 by Caleb Kraft 62 Comments

If you and your friends were gathering a pool of bets together as to when the first patent case would happen in 3d printing, someone just won the pot. 3D systems has filed suit against formlabs for possible patent infringement.

In a press release by 3D systems, they state that not only are they going after form labs, but also Kickstarter for selling the device.

Although Formlabs has publicly stated that certain patents have expired, 3D Systems believes the Form 1 3D printer infringes at least one of our patents, and we intend to enforce our patent rights

It is worth noting that the “cube” printer that Make magazine recently named the most reliable and easiest to use, happens to be made by 3D systems. Note that this one appears to be a typical rep-rap derivative.

[via Adafruit]

Blending Real Objects With 3D Prints

November 11, 2012 by Brian Benchoff 31 Comments

It’s very subtle, but if you saw [Greg]’s 3D printed stone to Lego adapter while walking down the street, it might just cause you to stop mid-stride.

This modification to real objects begin with [Greg] taking dozens of pictures of the target object at many different angles. These pictures are then imported into Agisoft PhotoScan which takes all these photos and converts it into a very high-resolution, full-color point cloud.

After precisely measuring the real-world dimensions of the object to be modeled, [Greg] imported his point cloud into Blender and got started on the actual 3D modeling task. By reconstructing the original sandstone block in Blender, [Greg] was also able to model Lego parts.After subtracting the part of the model above the Lego parts, [Greg] had a bizarre-looking adapter that adapts Lego pieces to a real-life stone block.

It’s a very, very cool projet that demonstrates how good [Greg] is at making 3D models of real objects and modeling them inside a computer. After the break you can see a walkthrough of his work process, an impressive amount of expertise wrapped up in making the world just a little more strange.

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NASA Is 3D Printing Rocket Engine Parts

November 11, 2012 by Brian Benchoff 26 Comments

In case you haven’t heard, NASA is building a new rocket – a replacement for the shuttle – that will eventually take crews again outside low Earth orbit. It’s called the Space Launch System and looks surprisingly similar to the Saturn V that took men to the moon. Manufacturing technology is light years ahead of what it was in the mid-60s, and this time around NASA is printing some rocket parts with selective laser melting.

Teams at the Marshall Space Flight center are melting metal powder together with lasers to produce parts for the new J-2X engine intended for use in the earth departure stage of the Space Launch System. While the 3d-printed parts haven’t seen a use in any live fire tests of the J-2X, the goal is to test these parts out later in the year and eventually have them man-rated, to carry astronauts to the moon, asteroids, or even Mars.

This isn’t the first time 3d printing has been used to make rocket engines. Earlier this year we saw [Rocket Moonlighting] build an entire rocket engine, powered by propane and NO2, using the same technology that NASA is using. [Moonlighting]’s engine is quite small, too small to lift itself off the ground, even. Still, it’s awesome to see 3D printing that will eventually take people into solar orbit.

MakiBox Turns Plastic Pellets Into 3D Objects

October 28, 2012 by Brian Benchoff 32 Comments

The holy grail of desktop 3D printers – aside from manufacturing full color objects in any shape imaginable – is turning tiny plastic pellets into a plastic filament. Many projects have attempted this with moderate levels of success but turning pellets into filament still an open problem. MakiBot hopes to solve this problem by manufacturing plastic filament just in time to be squirted out a nozzle onto the print bed.

MakiBox is seeing a lot of potential with their pellet drive. Instead of sending huge amounts of pellets into an auger extruder, the team realized the best option would be to send pellets into the hot end one at a time. This makes for better thermal characteristics and produces a very consistent filament.

Turning plastic pellets into 3D objects is an enticing idea but producing a filament on the fly is an interesting concept. While the MakiBox team is making custom color filament right now, in the future it might be possible to mix colors for full-color prints.

Videos demonstrating the extruder after the break.

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Finally, Turning Plastic Pellets Into 3D Printer Filament

October 22, 2012 by Brian Benchoff 47 Comments

Here’s the situation: a kilogram of 3D printer filament costs about $50. A kilogram of plastic pellets costs less than a tenth of that. Does anyone have a solution to this problem?

For years now, the general consensus was making your own 3D printer filament at home was nigh impossible, dealing with temperatures, pressures, and tolerances that home-built machines simply can’t handle. [Bradley] sent in a filament extruder he made because he was disturbed at this current mindset that desktop filament factories have huge technical issues that have yet to be overcome.

[Bradley]’s extruder is based on the Lyman Filament Extruder, a machine that has successfully demonstrated taking plastic pellets, forming them into a filament, and having this filament used in the production of 3D printed parts. [Bradley]’s improvements include a variable-speed motor, a larger hot end, and an automatic timing system to produce set quantities of printer filament.

Of course, since Inventables threw $40,000 at the problem of creating filament at home there were bound to be more than a few successful designs making their way out into the public. When we last covered the developments of home filament manufacturing, the Filabot seemed to be in the lead. Now with [Bradley] (and [Lyman])’s machines turning out usable filament, it’s only a matter of time before the 40 grand prize is snatched.

A Harpsichord That Plays Itself

October 19, 2012 by Mike Szczys 20 Comments

[Malcolm Messiter] is an Oboe player who loves to play pieces from the Baroque era. This often means playing with a Harpsichord and he managed to acquire one to call his very own. Unfortunately you can’t play both instruments at once so he set out to automate the keyboard. What you see here is a fully working version, but he soon went on to add solenoids to the upper rank as well. His story starts on page 27 of this newsletter (PDF).

He really went out of his way to make sure the instrument was not mistreated. A cabinet-maker built some brackets to mount the system above the keys. A friend drilled and tapped a sheet of acrylic to which each solenoid was mounted. The solenoid shafts have each been padded with felt to cushion the blow on the keys. We’ve embedded two demo video after the break that show off the first and second versions of the builds.

Harpsichords pluck the strings instead of hitting them with a hammer as the piano does. The mechanism that does the plucking had worn out on many of the keys so [Malcolm] used a 3D printer to help replace them.

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Reproduce 3D Printed Models By Making Your Own Molds

October 17, 2012 by Mike Szczys 36 Comments

Need fifty copies of that 3D printed whirligig you’re so proud of? It might be faster to just cast copies by using the 3D printed model to make a mold. [Micah] found himself in this situation and managed to cast one copy every 10-12 minutes using the mold seen above.

With the object in hand, you need to find a container which will fit the mold without too much waste. The bottom half of the mold is then filled with modeling clay, a few uniquely shaped objects to act as keys, and the model itself. After getting a good coating of release agent the rest of the mold is filled with a silicone rubber product which is sold for mold making. This creates one half of the mold. After it cures the clay and key objects are removed, everything is sprayed with the release agent, and the other half of the mold is poured.

Now your 3D object can be copied by pouring two-part resins in the to shiny new mold.