3D-Printable Sculpture Shows Off Unpredictable Order Of Chains

September 25, 2022 by Donald Papp 7 Comments

[davemoneysign] designed this fascinating roller chain kinetic sculpture, which creates tumbling and unpredictable patterns and shapes as long as the handle is turned; a surprisingly organic behavior considering the simplicity and rigidity of the parts.

3D-printed, with a satisfying assembly process.

The inspiration for this came from [Arthur Ganson]’s Machine With Roller Chain sculpture (video, embeded below). The original uses a metal chain and is motor-driven, but [davemoneysign] was inspired to create a desktop and hand-cranked manual version. This new version is entirely 3D-printed, and each of the pieces prints without supports.

According to [davemoneysign], the model works well with a chain of 36 links, but one could easily experiment with more or fewer and see how that changes the results. Perhaps with the addition of a motor this design could be adapted into something like this chains-and-sprockets clock?

You can see [Arthur Ganson]’s original in action in the video embedded below. It demonstrates very well the piece’s chaotic and unpredictable — yet oddly orderly — movement and shapes. Small wonder [davemoneysign] found inspiration in it.

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Filament Cutter Uses Unusual (But Effective) 3D-Printed Spring Design

September 23, 2022 by Donald Papp 12 Comments

When one needs a spring, a 3D-printed version is maybe not one’s first choice. It might even be fair to say that printed springs are something one ends up making, rather than something one sets out to use. That might change once you try the spring design in [the_ress]’s 3D-printed filament cutter with printed springs.

The filament cutter works like this: filament is inserted into the device through one of the pairs of holes at the bottom. To cut the filment, one presses down on the plunger. This pushes a blade down to neatly cut the filament at an angle. The cutter is the device’s only non-printed part; a single segment from an 18 mm utility knife blade.

The springs are of particular interest, and don’t look quite like a typical spring. They take their design from this compliant linear motion mechanism documented on reprap.org, and resemble little parallel 4-bar linkages. These springs have limited travel, but are definitely springy enough for the job they need to do, and that’s the important part.

Want a more traditional coiled spring? Annealing filament wound around a mandrel can yield useful results, and don’t forget the fantastic mechanisms known as flexures; they have clear similarities to the springs [the_ress] used. You can see her design in action in the short video, embedded below.

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Big 3D Printed BMO Is Also An OctoPrint Server

September 23, 2022 by Lewin Day 7 Comments

OctoPrint is a useful tool for 3D printers, providing remote access to essentially every 3D printer with a USB port. [Allie Katz] decided to build an OctoPrint server in the shape of a life-sized BMO from Adventure Time, and the results are cute as heck.

A Raspberry Pi 4 is the heart of the build, with [Allie] selecting a 8 GB model for the job. It’s paired with a Raspberry Pi touchscreen that serves as BMO’s face. The Pi is also given a stereo audio output board, and hooked up to a custom PCB that runs all of BMO’s buttons. Printing BMO itself was fairly straightforward, but requires some experience working with larger PETG parts. A useful note for those playing along at home is that Polymaker PolyLite PETG in teal is just about a perfect dupe for BMO’s authentic body color.

A bit of Python code animates BMO’s face and delivers funny quips at the press of a button. When it’s time to work, though, the touchscreen serves as a straightforward interface for OctoPrint. The resulting build is both fun and functional, and a great example of what 3D printing really can achieve. It’s a cute figurine and a functional print all in one, something we don’t see everyday!

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3D Printed String Vase Shows What’s Possible

September 20, 2022 by Lewin Day 15 Comments

Overhangs are the bane of the melty-plastic 3D printing world. Often, we try to avoid them with creative print alignments, or we compensate with supports. However, [3DPrintBunny] decided to embrace overhangs in the extreme in the design of her creative 3D-printed string vase.

The design is intended to be printed with a larger nozzle, on the order of 0.8 mm or so, at a layer height of 0.6 mm. Under these conditions, the printer nozzle bridges the gap between the vase’s pillars with a single string of molten filament. With the settings just so, the molten filament stays attached during the bridging operation, and creates a fine plastic string between the pillars. Repeat this across the whole design, and you get an attractive string vase.

Amazingly, [3DPrintBunny] didn’t have to do any fancy slicer tricks to achieve this. Stock slicer settings got the job done just fine, and she reports that the model should print on most FDM printers. For her own examples, she printed in a special silver/bronze dual color PLA filament.

It recalls us of efforts to create synthetic hair-like fibers by taking advantage of stringing in 3D printers. Video after the break. Continue reading “3D Printed String Vase Shows What’s Possible” →

Glass 3D Printing Via Laser

September 19, 2022 by Al Williams 5 Comments

If you haven’t noticed, diode laser engraver/cutters have been getting more powerful lately. [Cranktown City] was playing with an Atomstack 20 watt laser and wondered if it would sinter sand into glass. His early experiments were not too promising, but with some work, he was able to make a crude form of glass with the laser as the source of power. However, using glass beads was more effective, so he decided to build his own glass 3D printer using the laser.

This isn’t for the faint of heart. Surfaces need to be flat and there’s aluminum casting and plasma cutting involved, although some of it may not have been necessary for the final construction. The idea was to make a system that would leave a layer of sand and then put down a new layer on command. This turned out to be surprisingly difficult.

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3D Printable Bearings That Actually Work, No CAD Tweaking Required

September 17, 2022 by Donald Papp 22 Comments

3D printing bearings with an FDM printer can be an iffy endeavor, but it doesn’t have to be that way. [Matvey Kukuy]’s Ultimate 608 Bearing with Calibration Kit is everything you’ll need to dial in and print functional 608-style print-in-place bearings on your 3D printer.

Calibration pieces have a handy label attached for identification.

[Matvey] found that there are two key tolerances to get right. And by “get right” he means “empirically determine which works best with your filament and printer”. But don’t worry, there’s no need to get into CAD work to make that happen. [Matvey] has exported a staggering 64 slightly different calibration models (and their matching production versions) along with a printable testing tool. With the help of a step-by-step process that resembles a sort of binary search, one can take the Goldilocks approach to find just the right model for one’s filament and printer in a minimum of steps.

There’s one more tip as well: [Matvey] says that once you determine the best model to use, don’t fill the print bed with copies, unless you want a bed full of possibly non-working bearings! Why is this? A 3D printer prints a bed full of objects slightly differently than it prints a single one, and since the margin for error on the perfectly-selected bearing is so small, that can be enough to keep it from working. To print more than one bearing at a time, position them far from each other and use something like PrusaSlicer’s sequential printing, which is an option to print each object completely before starting the next one.

[Matvey]’s own best results came from printing with PLA at a layer height of 0.16 mm. He also used grease in the bearing to improve performance and extend its life. He doesn’t specify what kind of grease he used, but we’d recommend a plastic-safe grease like PTFE-based Super Lube.

Have you used 3D printed bearings in a project? Would [Matvey]’s design be helpful to you? Let us know all about it in the comments.

3D Printer Upcycles Computer Case To DAS

September 17, 2022 by Jonathan Bennett 29 Comments

Storage technologies are a bit of an alphabet soup, with NAS, SAN, and DAS systems being offered. That’s Network Attached Storage, Storage Area Network, and Direct Attached Storage. The DAS is the simplest, just physical drives attached to a machine, usually in a separate box custom made for the purpose. That physical box can be expensive, particularly if you live on an island like [Nicholas Sherlock], where shipping costs can be prohibitively high. So what does a resourceful hacker do, particularly one who has a 3d printer? Naturally, he designs a conversion kit and turns an available computer case into a DAS.

There’s some clever work here, starting with the baseplate that re-uses the ATX screw pattern. Bolted to that plate are up to four drive racks, each holding up to four drives. So all told, you can squeeze 16 drives into a handy case. The next clever bit is the Voronoi pattern, an organic structure that maximizes airflow and structural strength with minimal filament. A pair of 140mm fans hold the drives at a steady 32C in testing, but that’s warm enough that ABS is the way to go for the build. Keep in mind that the use of a computer case also provides a handy place to put the power supply, which uses the pin-short trick to provide power.

Data is handled with 4 to 1 SATA to SAS breakout cables, internal to external SAS converters, and an external SAS cable to the host PC. Of course, you’ll need a SAS card in your host PC to handle the connections. Thankfully you can pick those up on ebay for $20 USD and up.

If this looks good, maybe check out some other takes on this concept!