Cheap Ikea Camera Boom Ensures Shake-free Video

October 12, 2011 by Mike Nathan 19 Comments

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[Chris] recently got himself a nice web cam for documenting his Makerbot builds, and much like [Dino], he was looking for a way to get a bird’s-eye view of the action while keeping the camera nice and steady. While [Dino] ventured off to the hardware store, [Chris] tried a few different options that included tape, before heading off to Ikea to see what he could find.

$9 and a few Swedish meatballs later, he was on his way home with a “TERTIAL Work Lamp” that can be mounted on virtually any desk-like surface. He had to remove most of the web cam’s useless mounting hardware, doing the same with the lamp’s light fixture. He put together a small bracket in Google Sketchup, which he then printed out using his Makerbot.

It fit perfectly, and now he can get steady video of his Makerbot prints every single time.

3D-printable Laser Cutter

September 20, 2011 by Brian Benchoff 21 Comments

[peter] send in a reprappable laser cutter that he’s been working on. Even though he’s still having some problems with the accuracy of the beam over the entire square meter bed, it’s still an amazing build.

The build started off with a bunch of t-slot aluminum extrusions. After taking delivery of an absurdly large package containing a CO2 laser tube, [peter] started working on attaching motors to the axes. The optics travel the solid rods on pillow block bearings driven by the age-old stepper motor & timing belt drive.

The 1-square-meter of cut area on this machine is enormous for a homebrew laser cutter. [peter] discovered that once the necessary components are in place, it’s really how much aluminum you’d like to buy that becomes the limiting factor for the cut area. [peter] put the files for the 3D-printed carriages, brackets and mounts up on Thingiverse in the hopes his design can be improved by others.

Solar-powered RepRap Prints Even When The Power Is Out

September 15, 2011 by Mike Nathan 24 Comments

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[Mark] wrote in to share a little creation that he is calling the first solar-powered 3D printer in existence. While we can’t say that we totally agree with him on that title, we will give him the benefit of the doubt that this is the first solar-powered RepRap we have seen thus far.

You might remember [Mark] from his previous exploits, but rest assured that there’s little possibility of anyone losing an eye with this one. He has taken his RepRap outdoors, and with the help of a solar panel plus a few batteries from Harbor Freight, he has the world’s first solar-powered RepRap*.

The trick behind keeping the RepRap running for such a long time with the sun as its only power source lies in the RAMPS board [Mark] uses. He has the 1.3 revision of the shield, which enables him to print objects loaded from an SD card rather than requiring a computer to be connected at all times.

So, if you happen to need the ability to print 3D objects where an extension cord cannot possibly reach, check out [Mark’s] setup and get to building!

* Maybe. Perhaps.

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Making Better CNC Halftone Pictures

September 14, 2011 by Brian Benchoff 29 Comments

[Jason] was messing around with CNC machines and came up with his own halftone CNC picture that might be an improvement over previous attempts we’ve seen.

[Jason] was inspired by this Hack a Day post that converted a image halftone like the default Photoshop plugin or the rasterbator. The results were very nice, but once a user on the JoesCNC forum asked how he could make these ‘Mirage’ CNC picture panels, [Jason] knew what he had to do.

He immediately recognized the algorithm that generated the Mirage panels as based on the Gray-Scott reaction-diffusion algorithm. With this algorithm, dark areas look a little like fingerprints, meaning the toolhead of the CNC router can cut on the X and Y axes instead of a simple hole pattern with a traditional halftone. After a little bit of coding, [Jason] had an app that converted an image to a reaction-diffusion halftone which can then be converted to vectors and sent to a router.

It’s a very neat build and we imagine that [Jason]’s pictures would cost a bit less than the commercial panels. Check out the video after the break to see the fabrication process.

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A Laser Cutter Challenge

September 14, 2011 by Brian Benchoff 14 Comments

When the Louisville hackerspace LVL1 was discussing the purchase of a new laser cutter, a member said, “I could build one before you get around to buying one.” The gauntlet was thrown down, a challenge was set, and the race was on to build a tiny laser cutter before the hackerspace took delivery of their new laser cutter.

The mechanical aspect of the build is fairly simple. The X axis is simply a stepper motor, threaded rod and laser module mounted on a carriage. This carriage moves along the Y axis with the help of two stepper motors for either side. Everything was mounted on more perfboard than reason would suggest.

For the electronics of the project, three motor drivers were made with a few logic chips and the laser firing relay was stolen from test equipment developed for LVL1’s trans-Atlantic balloon build. Motor and laser control was handled by an Arduino to keep the build simple because the contest was over after the first laser was finished cutting a square.

LVL1 is now working on a second version of the winner of the laser cutter challenge. They’re planning on a touchscreen interface that will cut a plastic blank about the size of a credit card. We can’t wait to see the results of that build.

Huge DIY 3D Printer Predictably Prints Huge 3D Items

September 8, 2011 by Mike Nathan 36 Comments

Well, if we ever need something huge built on a RepRap, now we know who to call. [Jim] over at Grass Roots Engineering wrote in to share a large 3D print he just finished, which was extruded by an equally impressive home-built 3D printer.

The part he built consists of a bunch of hollow green tubing in a criss-cross pattern and was printed in just under 2 days. He never mentions what the part is going to be used for, but at 376 x 376 x 250mm (14.8 x 14.8 x 9.84in), he estimates that this is the biggest single part printed with a DIY 3D printer.

The printer itself is based on the RepRap, but is obviously far larger. It prints using ABS plastic utilizing a maximum build area of 403 x 403 x 322.7mm (15.86 x 15.86 x 12.7in). Built over the course of 3 years, it was fully operational in 2010 but has undergone several improvements as [Jim’s] needs have changed.

It’s a fantastic looking machine, and it seems to print quite nicely. We would sure love to have one of these in our workshop.

Continue reading to see [Jim’s] 3D printer in action.

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Freakin’ Huge CNC Router

September 4, 2011 by Brian Benchoff 22 Comments

[Tom] sent in a gigantic 3-axis router that he pieced together during a 2 week-long work experience placement. Looking at this picture showing a 12-inch ruler on the work area, we realized that this may be the largest CNC router we’ve seen on Hack A Day.

[Tom]’s employer gave him some obsolete axes, so piecing the mechanical components together was very easy. The only real problem was interfacing the CNC controller to a computer. This meant [Tom] had to convert G Code to the code used by the antiquated NSK axes. Where G Code defines arcs with a start point, end point, and radius, the NSK code defines arcs with a start point, end point, and another point along the arc. It’s a tricky bit of math, but [Tom] built some software that did this in Visual Basic.

Right now, [Tom] only has a pen tool attached to the router; you can check that in action after the break. We’re trying to imagine what we would do with a 4 m² work area; this could easily be used to make a giant reprap or other 3D printer.

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