Turning A MIG Welder Into A Metal 3D Printer

June 27, 2021 by Lewin Day 70 Comments

Metal 3D printers are, by and large, many times more expensive than their FDM and resin-based brethren. It’s a shame, because there’s plenty of projects that would benefit from being able to produce more heat-resistant metal parts with additive fabrication methods. [Integza]’s rocketry projects are one such example, so he decided to explore turning a MIG welder into a 3D printer for his own nefarious purposes. (Video, embedded below.)

The build is as simple as you could possibly imagine. A plastic adapter was printed to affix a MIG welding nozzle to an existing Elegoo Neptune 2 3D printer. Unfortunately, early attempts failed quickly as the heat from the welding nozzle melted the adapter. However, with a new design that held the nozzle handle far from the hot end, the ersatz metal 3D printer was able to run for much longer.

Useful parts weren’t on the cards, however, with [Integza] facing repeated issues with the steel bed warping from the heat of the welding process. While a thicker steel base plate would help, it’s likely that warping could still happen with enough heat input so more engineering may be needed. It’s not a new concept by any means, and results are typically rough, but it’s one we’d like to see developed further regardless.

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Custom 3D Printer Cart Hides Clever Features

June 26, 2021 by Tom Nardi 8 Comments

Even if you’ve got a decent sized workshop, there’s only so much stuff you can have sitting on the bench at one time. That’s why [Eric Strebel], ever the prolific maker, decided to build this slick cart for his fairly bulky Ultimaker 3 Extended printer. (Video, embedded below.) While the cart is obviously designed to match the aesthetics of the Ultimaker, the video below is sure to have some useful tips and tricks no matter which printer or tool you’re looking to cart around the shop in style.

[Eric] made a second video on sketching out the design.

On the surface this might look like a pretty standard rolling cart, and admittedly, at least half of the video is a bit more New Yankee Workshop than something we’d usually be interested in here on Hackaday. But [Eric] has built a number of neat little details into the cart that we think are worth mentally filing away for future projects.

For example, we really liked his use of magnets to hold the plastic totes in place, especially his method of letting the magnets align themselves first before locking everything down with screws and hot glue. The integrated uninterruptible power supply is also a nice touch, as it not only helps protect your prints in the event of a power outage, but means you could even move the cart around (very carefully…) as the printer does its thing.

But perhaps the most interesting element of the cart is that [Eric] has relocated the Ultimaker’s NFC sensors from the back of the printer and into the cart itself. This allows the printer to still read the NFC chip built into the rolls of Ultimaker filament, even when they’re locked safely away from humidity in a sealed box.

Now all you’ve got to do is apply for the loan it will take to pay for all of the MDF you’ll need to build your own version. At this point, we wouldn’t be surprised if encasing your 3D printer in metal would end up being cheaper than using wood.

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Casting A Simple 3D Print In Aluminium

June 25, 2021 by Lewin Day 21 Comments

3D printing with plastics and resins is great for quickly prototyping parts with all manner of geometries, but strength and durability of the parts produced is often limited. One way around this is to use your 3D printed parts as patterns for casting in something tougher like aluminium. That’s precisely what [Brian Oltrogge] did to produce an attractive wall hook from a 3D printed design.

The process starts with the design and printing of a wall hook, with [Brian] taking care to include the proper draft angles to allow the pattern to be properly removed from the mold. The print is carefully sanded down and post-processed to be highly smooth, so that it doesn’t spoil the mold when its removed for the casting process. From there, a sand casting mold is built around the pattern using sodium silicate in a 3-4% mix by weight with fine masonry sand. Once ready, the pattern is removed, and the mold is assembled, ready for the pour.

[Brian] completes the process with a simple gravity casting method using molten aluminium. The part is then removed from the mold, and filed down to improve the surface finish from the sand casting process. It’s then polished up to a nice shine and hung on the wall.

[Brian] does a great job of explaining the basics of what it takes to get gravity casting right; draft angles in particular are something often ignored by beginners, yet are crucial to getting good results. You needn’t just settle for casting inanimate objects though; we’ve featured DIY casting processes for gears before, too. Video after the break.

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Active Ball Joint Uses Spherical Gear

June 24, 2021 by Al Williams 40 Comments

A common CAD operation is to take a 2D shape and extrude it into a 3D shape. But what happens if you take a gear and replicate it along a sphere and then rotate it and do it again? As you can see in the video below, you wind up with a porcupine-like ball that you can transfer power to at nearly any angle. There’s a paper describing this spherical gear as part of an active ball joint mechanism and even if you aren’t mechanically inclined, it is something to see.

The spherical gear — technically a cross spherical gear — is made from PEEK and doesn’t look like it would be that difficult to fabricate. There’s also a simpler version known as a monopole gear in the drive system that provides three degrees of freedom.

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Print Your Own Flexures

June 22, 2021 by Chris Lott 12 Comments

Game developer and eternal learner [David Tucker] just posted a project where he’s making linear flexures on a 3D printer. Tinkerer [Tucker] wanted something that would be rigid in five of the six degrees of freedom, but would provide linear motion along one axis. In this case, it is for a pen or knife on a CNC flatbed device. [David]’s design combines the properties of a 1-dimensional flexure and a spring to give a constant downward force. Not only is this an interesting build in and of itself, but he gives a good explanation and examples of more traditional flexible constructs. He also points out this site by MIT Precision Compliant Systems Lab engineer [Marcel Thomas] which provides a wealth of information on flexures.

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3D Printing Food University Style

June 18, 2021 by Al Williams 5 Comments

While refitting a 3D printer for food printing isn’t really a new idea, we liked the detailed summary that appeared from a team from the University of Birmingham which converted an i3 clone printer to use a syringe extruder.

The syringe in question was meant for veterinarian use and is made of metal. The paper suggests that the metal is a better thermal conductor, but it was’t clear to us if they included a heating element for the syringe. In the pictures, though, it does appear to have some insulation around it. In any case, we imagine a metal syringe is easier to keep clean, which is important if you are depositing something edible.

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Printed Catamaran

June 15, 2021 by Al Williams 8 Comments

If you want to send some instruments out on the lake or the ocean, you’ll want something that floats. Sure, if you need to be underwater, or if you can fly over the water there are other options, but sometimes you want to be on the surface. For stability, it is hard to beat a catamaran — a boat with two hulls that each support one side of a deck. If that sounds like the ocean sensor platform of your dreams, try printing the one from [electrosync].

The boat looks super stable and has a brushless motor propulsion system. The design purpose is to carry environmental and water quality monitoring gear. It can hold over 5 kg of payload in the hull and there’s an optional deck system, although the plans for that are not yet included in the STL files.

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