A 3D printed roller coaster model with light strips modelling the trains

How To Make A Model Roller Coaster Without Any Moving Parts

July 20, 2022 by Robin Kearey 5 Comments

Roller coasters are not only great fun to ride, they’re also fascinating pieces of engineering. Building your own full-size coaster is sadly beyond most people’s means, so the average enthusiast will have to settle for simulation or modelling of their own designs. [Jon Mendenhall] is one of those who specialize in building model roller coasters and simulating their motion in intricate detail. His latest project is a scale model of VelociCoaster, a Jurassic Park-themed ride in Universal’s Islands of Adventure, that simulates the coaster’s ride without using any moving parts.

[Jon] achieves this by re-creating the trains’ motion using LED strips. A total of 3000 LEDs are spread along more than nine meters of track and make a mesmerizing light show of several trains whizzing along the track, accelerating and slowing down exactly like the real thing.

In his video, [Jon] explains the process of generating an accurate 3D model of the track starting from nothing more than an overhead view of the park as well as photos taken from various angles. The surrounding terrain and buildings are also included in his 3D model, as are the 128 supports that hold the track in place. The terrain and building were made from plywood and foam using a CNC machine, while the track and supports were 3D printed.

A Teensy microcontroller runs the whole show, with the LED strips split into five separate sections to allow a high enough frame rate for smooth animations. An infrared remote is used to start and stop the ride, as well as to adjust the speed; the model supports running the trains at a physically accurate speed, but because this looks rather dull, the regular setting is about three times as fast.

Looking for more roller coaster models? [Jon] made a similarly impressive model with a powered train before, and we’ve seen several models that actually coast along their tracks.

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3D Printed Skate Trucks Do Surprisingly Okay

July 20, 2022 by Lewin Day 18 Comments

If you can buy something off the shelf, there’s a good chance that someone has tried to 3D print their own version. [Daniel Norée] did just that with skateboard trucks, whipping up a design of his own.

The main body of the trucks is 3D-printed, as is the hanger. A 195 mm M8 threaded rod is then used through the center of the trucks in order to provide an axle for fitting the wheels and bearings themselves. He 3D-printed the parts using a carbon-fiber reinforced nylon with the slicer set up to maximize strength. In testing, they rolled around the neighbourhood just fine.

[Mayer Makes] found the design online, and 3D printed some using his own transparent high-impact resin, making a cool set of clear-ish trucks. It’s a tough material, which we’ve featured on this site before.

Those trucks ended up in the hands of [Braille Skateboarding], who put them through their paces. The trucks are loose, but take a good beating around the park. Eventually one of the trucks succumbs after landing many kickfilps and ollies on the concrete.

Other great skate hacks include casting your own wheels in a 3D-printed mold. Video after the break.

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Ask Hackaday: Resin Printer Build Plates

July 20, 2022 by Al Williams 29 Comments

The early days of FDM 3D printing were wild and wooly. Getting plastic to stick to your build plate was a challenge. Blue tape and hairspray-coated glass were kings for a long time. Over time, better coatings have appeared and many people use spring steel covered in some kind of PEI. There seem to be fewer choices when it comes to resin printers, though. We recently had a chance to try three different build surfaces on two different printers: a Nova3D Bene4 and an Anycubic Photon M3. We learned a lot.

Resin Printing Review

If you haven’t figuratively dipped your toe into resin yet — which would literally be quite messy — the printers are simple enough. There is a tank or vat of liquid resin with a clear film on the bottom. The vat rests on an LCD screen and there is a UV source beneath that.

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Liquid Piston Engine Finally Works

July 15, 2022 by Al Williams 7 Comments

The first video from [3DPrintedLife] attempting to make a liquid piston engine was… well… the operative word is attempting. The latest video, though, which you can see below gets it right, at least eventually.. He has a good explanation of the changes that made the design better. Turns out, one change that made a difference was to turn a key part of the engine inside out. You can see the video below.

The first version would quickly break during operation and while the first new version didn’t work very well, it did stay in one piece which is a definite improvement.

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You Wouldn’t 3D Print A House, Would You?

July 13, 2022 by Matthew Carlson 66 Comments

Most houses built in the US today are platform construction: skinny two-by-fours are stacked and layered to create walls with studs. Each floor is framed on top of the other. It is fast, relatively cheap, and easy to learn how to do. However, it is not without drawbacks. Some estimates put the amount of waste generated per square foot (0.09 m²) at around 3.9 lbs (1.8 kg).

Timber framing is an older style where giant beams are used to create the structure of the house. Each timber is hand-carved and shaped, requiring skill and precision. Some cabins are still built this way because it is easy to source the timber locally and cutting into big logs is less work than cutting into lots of small logs. It’s relatively ecologically friendly, but slow and skilled-labor intensive.

We live in a world where there is a vast need for cheaper, faster, more eco-friendly housing, but finding a solution that can tick all the boxes is fiendishly difficult. Can 3D-printed housing accomplish all three of those goals? We’re not there yet, but we’re working on it.

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When Combat Robot Wheels Need To Be Nice And Cheap (But Mostly Cheap)

July 10, 2022 by Donald Papp 11 Comments

It started with [CHORL] making a promise to himself regarding constructing a new combat robot: no spending of money on the new robot.

That rule was violated (but only a little) by making his robot’s wheels out of EVA kneeling pads. EVA (Ethylene-Vinyl Acetate) is a closed-cell foam that makes for durable yoga mats, kneeling pads, and products of a similar nature. [CHORL] found a way to turn them into light but serviceable wheels for his robot: the Susquehanna Boxcar.

Nested hole saws create concentric holes. Perfect for wheels.

Here’s how the wheels were made: [CHORL] began with two hole saws. Nesting a smaller hole saw into a larger one by putting both on the same arbor created a saw with two holes, both of which were centered with respect to one another. The only problem was that this hole saw was not actually deep enough to cut completely through the thick foam. Luckily, cutting roughly halfway through on one side, then flipping the sheet over and cutting through from the other side was a good workaround. That took care of turning the thick foam sheet into round wheels.

A 3D-printed part served as a wheel hub as well as gear for the drivetrain. We want to call attention to the clever method of reinforcing the connection between the parts. [CHORL] didn’t want to just glue the geared hub directly to the surface of the foam wheel, because he suspected it might separate under stress. To address this, he designed six slots into the hub, cut matching slots into the foam wheel, and inserted six spline-like reinforcements in the form of some ABS strips he had on hand. Gluing it all together with E-6000 and leaving it to cure overnight under a weight resulted in a geared wheel assembly that [CHORL] judged to be about as round and rigid as a wheel should be, so the robot had a solution for nice light wheels that were, above all, cheap!

Lots of robots need wheels, and unsurprisingly, DIY solutions are common projects. [CHORL]’s approach here looks pretty scalable, as long as one can cut some accurate holes.

Interested in knowing more about the robot these wheels are destined for? [CHORL]’s still working on the Susquehanna Boxcar, but it’s almost done, and you can read a bit more about it (and see a few more pictures) here.

Vapor Trails And Fan Make For Fantastic Photos In DIY Wind Tunnel

July 10, 2022 by Donald Papp 4 Comments

Every wanted a mini wind tunnel to check the aerodynamics of scale model cars, drones, or other small objects? Then check out [dannyesp]’s mostly-3D-printed DIY wind tunnel (video, embedded below). Don’t forget to also browse the additional photos in this Reddit thread.

A junk parts project doesn’t have to *look* like a hack job.

There’s not much for plans available, since as [dannyesp] admits, this device was very much the product of trial-and-error and junk bin parts. The video and photos are more than enough for any enterprising hacker to work with.

The core of the device is a large fan made from a junked drone motor. This fan is located at the rear of the tunnel. A small anemometer is placed at the front, where some 3D-printed baffles also work to smooth out turbulent incoming air.

The foggy trails of vapor come from a hacked-up vape pen. Vapor gets piped through some tubing to the front of the tunnel. There, the vapor trails are drawn towards the low-pressure area at the rear, traveling over and around the object on the way. [dannyesp] also mentions that the platform holding the object is mounted on a rail, which incorporates some kind of pressure sensor in an attempt to quantify wind drag.

We want to take a moment to appreciate just how clean this “junk parts” project looks — even though it is made from things like broken photo frames. All of this comes down to thoughtful assembly. A hack doesn’t have to look like a hack job, after all. We also love the little control box that, instead of having a separate power indicator, lights up like a little nightlight when it has power.

Hacking vaporizers is a fantastic way to create a small, portable fog machine. These can create fantastic costume effects like this smoking Ghost Rider skull. They are a great way to turn an off-the-shelf consumer item into something that cost quite a bit more just a few years back.

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