Nanoscale 3D Printing

March 14, 2012 by Brian Benchoff 17 Comments

This 3D-printed model of the Tower Bridge is only 200 micrometers long. To put that into perspective, the distance between the towers is the width of a human hair. This model is the product of research at the additive manufacturing department of the Vienna University of Technology

The models were fabricated much like normal stereolithography – a laser shines onto a vat of light-sensitive resin. The resin hardens when exposed to light, and the model is built up layer by layer. These nanoscale models were made using a process called “two-photon lithography,” something we’re not going to pretend we understand completely but here’s a nice paper that provides a good overview. Needless to say, the precision these prints exhibit are nearly ludicrous. The researchers claim a precision of ±1µm, a respectable amount of precision for very high-tech machining applications.

The researches posted a video of the fabrication of a nanoscale F1 race car filmed in real-time. Check that out after the break.

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3D Printing From An Android Device

March 10, 2012 by Brian Benchoff 5 Comments

[skullkey] over at the House4Hack hackerspace in Pretoria, South Africa wanted a way to get kids excited about technology and desktop fabrication labs. Wanting to give kids a visceral feel for the march of technology, he created Makerdroid, an android app that allows for the creation 3D objects on an Android tablet and preparing them to be printed on a Reprap or Makerbot.

What’s really interesting about this build is not only the fact that [skullkey] and his lovely beta testers are generating .STL files on an Android device, the object files are also being converted to GCode on the Android, without the need for a conventional computer. Makerdroid uses the very popular Skeinforge to generate the instructions for the printer (although a lot of people are switching over to Slic3r).

Makerdroid doesn’t need a PC to print objects out on a 3D printer, but we think the process of shuffling GCode files from a tablet to the printer with an SD card is a little archaic. It might be possible to print directly from an Android tablet over Bluetooth with the Android Bluetooth Reprap app that is currently in development. Still, we love the idea of printing objects we just created on a touch screen, as shown in the Makerdroid demo video after the break.

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New Extruder 3D Prints Tasty Treats Using Chocolate

February 29, 2012 by Mike Szczys 18 Comments

If you’ve never felt at home with a piping bag in your hands this chocolate extruder will come to your rescue. It can replace the plastic extruder head on your 3D printer (RepRap, Makerbot, most 3-axis CNC machines, etc.), letting you turn your digital creations into decadent reality.

The head uses a progressive cavity pump to feed the chocolate from a reservoir through the printing nozzle. It’s important to keep the chocolate warm or it will set up so when [Tomi Salo] designed the print head he included a heat shroud through which warm air can be circulated. He uses a shoe dryer to source the hot hair which is patched into the heat shroud with a length of tubing.

This extruder can be 3D printed but be careful what material you use. [Tomi] mentions that PLA is ‘sort of food-safe’ but ABS is not. We wonder if the design could be altered for milling out of aluminum or stainless? At any rate, if you’re going to give it a try you might find [Tomi’s] advice on working with chocolate useful.

[via @clothbot]

3D Printed Lugs For Your Custom Bike

February 24, 2012 by Mike Szczys 39 Comments

We haven’t heard much about 3D printing using stainless steel as the medium, but that’s exactly what’s going on with the lugs used to assemble this bicycle frame. They’re manufactured using LaserCusing, which is a brand name for parts produced using Selective Laser Melting. The video after the break gives you an overview of what it takes to clean up each of these parts.

The laser melts metal power to solidify areas needed in the final part. Just like the hobby printing we’ve seen on the RepRap or Makerbot there are structural supports necessary to complete the print job, and these need to be removed after the laser has done its work. This is where the majority of the labor comes in. You’ll see a ton of waste material pulled out of the cage-like lug, and we’re sure there’s no shortage of filing and polishing to finish up. But wow, what an interesting result. We just need to figure out if anyone has found a cost-effective way to hack together one of these metal-powder printers.

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