Saving Birds With 3D Printed Boats

May 31, 2022 by Bryan Cockfield 22 Comments

Montana, rightfully nicknamed the big sky country, is a beautiful state with abundant wide open landscapes, mountains, and wildlife. It’s a fantastic place to visit or live, but if you happen to reside in the city of Butte, that amazing Montana landscape is marred by the remnants of an enormous open pit mine. Not only is it an eyesore, but the water that has filled the pit is deadly to any bird that lands there. As a result, a group of people have taken to some ingenious methods to deter birds from landing in the man-made toxic lake for too long.

When they first started, the only tool they had available was a rifle. Scaring birds this way is not the most effective way for all species, though, so lately they have been turning to other tools. One of which is a custom boat built on a foam bodyboard which uses a plethora of 3D printed parts and sensors to allow the operator to remotely pilot the boat on the toxic lake. The team also has a drone to scare birds away, plus an array of other tools like high-powered lasers, propane cannons, and various scopes in order to put together the most effective response to help save wildlife.

While this strategy runs the gamut of the tools most commonly featured here, from 3D printers to drones to lasers, the only thing that’s missing is some automation like we have seen with other drone boat builds we’ve featured in the past. It takes quite a bit of time to continually scare birds off this lake, even through the winter, so every bit of help the team can get could go even further.

Continue reading “Saving Birds With 3D Printed Boats” →

Ultra Light VORON X-Beam Milled From Aluminium Tube Stock

May 31, 2022 by Maya Posch 49 Comments

When it comes to 3D printing using fused deposition modeling (FDM) technology, there are two main groups of printers: Cartesian and CoreXY, with the latter being the domain of those who wish to get the fastest prints possible, courtesy of the much more nimble tool head configuration. Having less mass in the X/Y carriage assembly means that it can also move faster, which leads to CoreXY FDM enthusiasts to experiment with carbon fiber and a recent video by [PrimeSenator] in which an X-beam milled out of aluminium tube stock that weighs even less than a comparable carbon fiber tube is demonstrated.

As the CoreXY FDM printer only moves in the Z-direction relative to the printing surface, the X/Y axes are directly controlled by belts and actuators. This means that the faster and more precise you can move the extruder head along the linear rails, the faster you can (theoretically) print. Ditching the heavier carbon fiber for these milled aluminium structures on a Voron Design CoreXY printer should mean less kinetic inertia, with the initial demonstrations showing positive results.

The interesting thing about this ‘speed printing’ community is that not only the raw printing speeds, but also that in theory CoreXY FDM printers are superior in terms of precision (resolution) and efficiency (e.g. build volume). All of which makes these printers worthy of a look next time one is shopping for an FDM-style printer.

Continue reading “Ultra Light VORON X-Beam Milled From Aluminium Tube Stock” →

3D Printing A Water-Cooled Jet Engine?

May 30, 2022 by Dave Rowntree 14 Comments

Everybody knows the trick to holding a candle flame to a balloon without it bursting — that of adding a little water before the air to absorb the heat from the relatively cool flame. So [Integza], in his quest to 3D print a jet engine wondered if the same principle could applied to a 3D printed combustion chamber. First things first, the little puddle of water was replaced with a pumped flow, from an external reservoir, giving the thin plastic inner surface at least a vague chance of survival. Whilst this whole plan might seem pretty bonkers (although we admit, not so much if you’ve seen any of other videos in the channel lately) the idea has some merit. Liquid cooling the combustion jacket is used in a great many rocket engine designs, we note, the German WWII V2 rocket used this idea with great success, along with many others. After all, some materials will only soften and become structurally weak if they get hot enough in any spot, so if it is sufficiently conductive, then the excess heat can be removed from the outer surface and keep the surface temperature within sensible bounds. Since resin is a thermoset plastic, and will burn, rather than melt, this behaviour will be different, but not necessarily better for this application.

The combustion chamber itself didn’t burn

The issue we can see, is balancing the thermal conductivity of the resin wall, with the rate of cooling from the water flow, whilst making it thick enough to withstand the pressure of combustion, and any shock components. Quite a complicated task if you ask us. Is resin the right material for the job? Probably not, but it’s fun finding out anyway! In the end [Integza] managed to come up with a design, that with the help of a metal injector separator plate, survived long enough to maintain some sort of combustion, until the plate overheated and burned the resin around its support. Better luck next time!

This isn’t the first time attempting to use 3D printed resin for such an application, here’s an attempt to use the air-multiplier type setup with a combustion chamber. Of course making a combustion chamber from a toilet roll holder is far more sensible, just as [colinfurze] will attest, don’t try this at home folks!

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3D Print Glass With A Laser Cutter

May 28, 2022 by Jenny List 15 Comments

We’re all familiar with FDM 3D printing, and some of the more well-heeled or adventurous among us may even have taken a faltering step into the world of SLA printers. But for most of us there’s a step further in 3D printing that remains beyond our reach. SLS, or Selective Laser Sintering, creates prints from powder by melting it layer by layer using a laser, and has the advantage of opening up more useful materials than the polymer stock of the other methods. It’s not entirely unreachable though, as [Kenneth Hawthorn] shows us by using a laser cutter to produce SLS prints from powdered glass.

He evolved the technique of repeated fast passes with the laser to gradually melt more glass together as opposed to slower passes. He achieved a resolution as low as 0.1 mm, though he found a better glass color when the laser was less tightly focused. It raises the concern that glass powder is abrasive and thus a threat to any mechanism, thus he’s being extremely careful with the fan settings.

This may not be quite in the league of an SLS printer costing thousands of dollars, but it’s a technique that bears more investigation and could no doubt be refined for more custom fused glass creations. He tells us he was inspired by a previous Hackaday post about sintering sand, and of course we’d like to remind readers of a 3D printer that did the same job with the power of the sun.

Tame Your Flexible Filaments With This Belt-Drive Extruder

May 25, 2022 by Dave Rowntree 8 Comments

[Proper Printing] clearly enjoys pushing the boundaries of 3D printed materials, and sometimes this requires building custom 3D printers or at least the business end of them. Flexible filaments can be a bit of a pain to deal with, simply because most extruders are designed to push the filament into the hot end with a simple hobbed bolt (or pinch roller setup) and only work reliably due the rigidity of the plastic itself. Once you go flexible, the rigidity is reduced and the filament often deflects sideways and the extruder jams. The longer the filament path leading to the hotend, the harder it gets. The dual belt drive extruder (they’re calling it ‘proper extruder’) grips the filament on two sides with a pair of supported belts, guiding it into the hotend without allowing it to deflect sideways. The extruder body and gears were resin printed (but, we checked — the design is suitable for FDM printing as well) proving that resin printing on modern printers, does indeed maintain adequate dimensional accuracy allowing the building of mechanisms, despite the naysayers! Continue reading “Tame Your Flexible Filaments With This Belt-Drive Extruder” →

3D Printing Fabrics Is Easier Than You Think

May 24, 2022 by Lewin Day 15 Comments

Conventional textiles made of woven threads are highly useful materials. [Sara Alvarez] has had some success creating fabric-like materials through 3D printing, and though they’re not identical, they have some similar properties that make them unique and useful.

Fabrics are made by the weaving or knitting together many threads into a cohesive whole. [Sara]’s 3D-printed fabrics are different, since the printer can’t readily weave individual fibers together. Instead, a variety of methods are used to create similar materials.

The simplest is perhaps the chainmail method, where many small individual links join together to make a relatively rigid material. Alternatively, G-code or careful modelling can be used to create fabric-like patterns, which are printed directly in flexible material to become a fabric-like sheet. Finally, the infill method takes advantage of code inbuilt to a slicer to create a pattern that can be 3D-printed to create a fabric like material by removing the top and bottom layers of the print.

[Sara] demonstrates creating a simple “fabric” swatch using the slicer method, and demonstrates the qualities of the finished product. She also shows off various applications that can take advantage of this technique.

If you’re a 3D-printing enthusiast who also loves making clothes and apparel, consider printing up some shoes – like these we’ve seen before. Video after the break. Continue reading “3D Printing Fabrics Is Easier Than You Think” →

Bi-Color Filament Kicks 3D Printed Optical Illusions Up A Notch

May 22, 2022 by Donald Papp 2 Comments

A new video from [Make Anything] shows off a nice combo that has a real visual impact: ambiguous shapes that look different depending on what angle they are viewed at, combined with an unusual filament that enhances the effect greatly. As you can see in the image above that shows off just such an object in front of a mirror, the results are pretty striking.

Japanese mathematician and artist [Kokichi Sugihara] figured out the math behind such objects, of which his ambiguous cylinder illusion is probably the most well-known. That inspired [Make Anything] to create his own strange objects, which he showcases happily. He adds one more twist, however.

This filament is split right down the middle in two colors.

What is a natural complement to an object that looks different based on the direction from which it is viewed? A filament whose color depends on what direction it is viewed, of course! The filament in question is MatterHackers Quantum dual-color PLA, and this unusual filament is split right down the middle in two different colors, resulting in a printed object whose exact color depends entirely on the viewing angle, and the object geometry.

The resulting objects look especially striking when demonstrated with the help of a mirror, because as the object turns and changes, so does the color change as well. You can watch it all in action in the video below (embedded after the page break) which showcases quite a few different takes on the concept, so check it out to see them all.

3D printing has certainly opened up a new doors when it comes to brain-bending optical effects, like this hypnotic Moiré pattern, and perhaps dual-color filament can enhance those as well.

Continue reading “Bi-Color Filament Kicks 3D Printed Optical Illusions Up A Notch” →