Generate Fully Parametric, 3D-Printable Speaker Enclosures

November 28, 2021 by Donald Papp 9 Comments

Having the right speaker enclosure can make a big difference to sound quality, so it’s no surprise that customizable ones are a common project for those who treat sound seriously. In that vein, [zx82net]’s Universal Speaker Box aims to give one everything they need to craft the perfect enclosure.

The parts can be 3D-printed, but the design ensures that the front and back panels are flat, so one can use wood or some other material for those depending on preference and appearance. The assembly is screwed together using six M3 bolts per side with optional heat-set inserts, but it’s entirely possible to simply glue the unit together if preferred.

One thing that makes this design a bit more broadly useful is that [zx82net] not only provides the parametric design file for Fusion360, but also includes STEP format CAD files, and a small number of pre-configured assemblies for a few commonly available speaker drivers: the Dayton Audio DMA70-4, ND91-4, and the TCP115-4. Not enough for you? Check out [zx82net]’s collection of ready-to-rock enclosures in a variety of designs and configurations; there’s bound to be something to appeal to just about anyone.

[via Reddit]

The Trials And Tribulations Of SLA Printing A Portable Wii Handheld

November 28, 2021 by Lewin Day 9 Comments

The G-Boy kit revolutionized the subculture around building portable home consoles, allowing an entire Wii to be crammed into a form factor the size of a original Game Boy. [Chris Downing] is no stranger to the field, and sourced a G-Boy kit of his own to build it to the best of his abilities. (Video embedded after the break.)

However, he wanted to step up above the FDM-printed parts of the original kit. Thus, he contacted the kit developer Gman, who provided him with the 3D model files so he could attempt a higher-quality SLA print himself. [Downing] had some experience with SLA printing in the past with the Form 2, but found some unique challenges on this build with the Form 3.

The benefits of SLA printing are the finer detail and surface finish it delivers. This is particularly nice on things like enclosures and buttons which are handled regularly by the user. However, the standard resin that ships with the Form 3 had issues with warping, particularly on thin flat walls which make up the majority of the G-Boy case.

Other issues included the fact that the standard cured SLA resin is much harder to thread screws into than softer FDM plastic, something which frustrated assembly of the design. It’s also brittle, too, which leads to easy breakages.

As a fan of a properly finished product, [Downing] decided to sand and paint the enclosure regardless. Tragedy struck when the spray cans started to spit chunks due to being over a year old. However, it serendipitously turned into a win, producing an attractive granite stone-like finish which actually looks pretty good.

The G-Boy kit took Wii portable builds mainstream, and drew many new builders into the subculture. [Downing] may be a stalwart of the scene, but still learned new skills along the way of the build.

We can’t wait to see what happens next in the scene, though we’d suspect someone’s already out there chopping up a rare PlayStation 5 as we speak.

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Want Octoprint But Lack A Raspberry Pi? Use An Old Android Phone

November 27, 2021 by Donald Papp 21 Comments

3D printers and Octoprint have a long history together, and pre-built images for the Raspberry Pi make getting up and running pretty easy. But there’s also another easy way to get in on the Octoprint action, and that’s to run it on an Android phone with the octo4a project.

A modern smartphone has a lot of useful features that make it attractive as an Octoprint host. There is a built-in touchscreen, easy power management, a built-in camera, and the fact that people regularly upgrade to new phones means that older Android phones — still powerful pieces of hardware in their own right — are readily available at low cost. The project is still relatively new, so don’t forget to check the Octoprint community thread for this project if you give it a try.

If you are wondering what Octoprint is and what it brings to the table, our own Tom Nardi explained what it does and why it matters when he shared his own upgrade experience from 2018. A few details are no longer current — for example one is no longer likely to encounter a Printrbot — but it’s still a perfectly valid primer on adding great management functionality to a 3D printer.

Fifty Shades Of Brown: 3D Printing With Sugar

November 25, 2021 by Dave Rowntree 20 Comments

[Norbert Heinz] has been busy for the 2021 Hackaday Prize entry, working on the design of a direct granule extruder for 3D printing with waste materials, or materials that are not provided in the form of a filament. Sugar is pretty common in most households, so since that’s already available in granular form, [Norbert] gave 3D printing with granulated sugar a try. (Video, embedded below.)

[Editor’s note: He earned fifth place for this one! Well, not the sugar in particular, but the overall great work on granular extruders.]

Success was somewhat variable, as the gloopy material is notoriously fickle to work with, but the setup did produce some structures that stayed in one piece, at least for a while. Initially [Norbert] tried it real slow, effectively printing with the liquified sweet stuff, by dragging a molten blob of it around on the end of the extruder nozzle. Whilst this did work, the resulting print resolution did leave something to be desired. The next thing tried was increased print speed. This produced clearer prints, as the sugar did not have time to caramelise, or form a noticeable blob, but as soon as the bed started to cool, it caused it to crack badly.

Going slow seemed to be the way forward, as more time to cool may have reduced the stresses in the structure due to the increased cooling time. But anyway, the way we see it, is it’s fun trying, and if it fails, you can just eat it, so long as you disregard all that food safety stuff anyway.

[Norbert] documents the granule extruder journey on the project Hackaday.io page, so it should be straightforward enough to duplicate this is you were so inclined.

We’ve covered a few sugary hacks before; Need a renewable bed adhesive? out of glue stick? try sugar as a bed adhesive! Printing in gloopy, sloppy materials is nothing new at all, we covered it nearly ten years ago.

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E-MonoWheel

November 24, 2021 by Matthew Carlson 16 Comments

Generally, monowheels are that wacky, wildly futuristic transport that we lump in the same category as hoverbikes and jetpacks: strange, currently impractical, but very cool. Not content with waiting for the distant future, [Sam Barker] made his own electric monowheel. (Video, embedded below.)

The hardest part of any monowheel is that the outside rim needs to stand enormous abuse. It supports the weight of the vehicle and provides most of the structural integrity, but also is the means of propulsion. [Sam]’s first thought was to use a trampoline frame as it is a round and reasonably sturdy tube steel. He 3D printed the rollers that connected the subframe to the trampoline frame. Flat bar stock was used to make the angles inside the subframe and straight tube steel connected the inner frame into a trapezoid. The trampoline frame was welded together and on the first test spin, it broke apart from the stress. It simply wasn’t strong enough.

Not to be dissuaded, he found a company that bends steel into custom shapes. He stole the e-bike kit from another bike he had converted earlier, and the wheel was turning. Some handles and foot-pedal later, it was time for a proper test drive. Overall, the result is pretty impressive and the double-takes [Sam] gets while riding down streets in town are wonderful. If you’re looking to scratch the monowheel itch, check out this wooden monowheel.

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Significantly Improved Egg Timer Makes Pictionary Better

November 23, 2021 by Lewin Day 24 Comments

The traditional sand timer, known colloquially as an egg timer, served its purpose well over the centuries since its development. However, [MakerPaul] realised it had some significant flaws that were ruining Pictionary, and set out to fix the problem.

If you’re not looking directly at an egg timer, it’s easy to miss the moment when the timer runs out. Resetting the timer before it runs out also requires waiting for the sand to filter to one side. Clearly the world needs a better mousetrap.

The tipping timer from [MakerPaul] solves both those issues. In this design, sand flows down into an offset area, which tips the device over when reaching a certain time limit. Additionally, turning the device upside down and then rotating it instantly reloads the sand, meaning the timer can be reused immediately.

[MakerPaul] first came up with the idea about 20 years ago, refining it during the recent lockdowns. The design files are freely available for anyone that wishes to build one. [MakerPaul] isn’t commercializing the idea, but mentions that it would be great if anyone using it makes a donation to the Mind mental health charity.

Most timers we feature are electronic and digital, but it’s easy to appreciate the elegance of what [MakerPaul] has achieved here. As a bonus, he documented the entire project and its application in under 90 seconds. How good is that? Video after the break.

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Ender 3 Meets MIG Welder To Make A Metal Benchy — Kind Of

November 23, 2021 by Dan Maloney 20 Comments

When you can buy a 3D printer at Aldi, you pretty much know that 3D printing has been reduced to practice. At least for the plastic version of 3D printing; metal printing is another thing entirely. It’s easy to squeeze out a little molten plastic in a controlled fashion, but things get a little more — energetic — when you try to do the same with metal.

At least that’s what [Lucas] has been experiencing with his attempts to build a metal 3D printer over on his Cranktown City YouTube channel. Granted, he set himself up for a challenge from the get-go by seeking to stick a MIG welder onto an Ender 3, a platform that in no way was ready for the abuse it was about to endure. Part 1 of the video series below shows the first attempt, which ended badly for both the printer and for the prints.

But that first prototype, melted parts notwithstanding, gave [Lucas] enough to go on for the improvements of version 2, including a better build plate, heat shielding for the printer’s tender bits, and a legit MIG welder wire feeder. [Lucas] also built current control in, with a clever non-destructive interface to the welder controls. These improvements were enough to attempt a Benchy print, which started out pretty decent but got a bit droopy toward the end.

As imperfect as it is, the Benchy is a vast improvement over the formless blobs from version 1, and the printer holds quite a bit of promise for the future. One thing you can’t accuse [Lucas] of is giving up on a project too easily; after all, he built a laser cutter from scratch, including the laser tube.

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