Delta Robot 3D Printer

September 4, 2011 by Brian Benchoff 22 Comments

Sometimes, not all our builds work out the way we hoped. That’s what happened to [Rob] and his attempt at a Delta robot that does stereo lithography. A Delta robot is capable of very fast and precise movements, so [Rob] slapped a laser module on the end of the arms. After putting some UV curing resin in front of the laser, he was left with a blob of goo and we’re trying to figure out why.

[Rob] thinks the admittedly terrible print quality was due to diffraction and the reflective build plate. If this were the case, we’d agree with the assessment that adding some dye to the resin would help. Some commentors on [Rob]’s blog have suggested that he’s running the laser too slowly. It’s a shame [Rob] scrapped his build and turned it into a plain-jane X & Y axis build. Delta robots can be really damn fast, and adding a printer to one might mean prints that take minutes instead of hours. There are a few people working to get a Delta RepRap off the ground, but this project still has another prototype or two before that happens. Check out [Rob]’s attempt at Delta robot stereolithography after the break.

Thanks to [techartisan] for sending this one in.

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Building A CNC Router To Call My Own

September 1, 2011 by Jeremy Cook 17 Comments

As with most writers for [HAD], I enjoy doing projects as much as I like writing about them. As a mechanical Engineer that writes for a blog mostly about electronics, a CNC router seemed like something I needed in my garage. Building a router like this requires a bit of expertise in both electronics and mechanics, so it seemed like a good challenge.

This router kit, made by Zen Toolworks, comes fairly complete frame-wise, but requires a lot of knowledge on the electrical side to get things running correctly. In order to make it look decent and work correctly, I had to rely on some zip-tie and basic diagnostic skills that I’ve honed as a former engineering Co-op and technician. Also, I had to figure out a way to cheaply stack everything in my garage as we park two cars there (the footprint is 14″ x 22″, so I consider that a success).

One of the bigger challenges that I still have to overcome with this project is learning “G-code” and how to use software to generate it. Although I’ve done some basic programming already, as seen in the video after the break, there’s still much to learn. I’d hope that having this tool around can lead to better projects as I won’t have to be restricted to simple milled lines and circles anymore.

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Milling Curves Into Mirrors And Glass

August 26, 2011 by Mike Szczys 18 Comments

[Ben Krasnow] is working on a project that uses an extremely expensive specialty mirror. He needed to cut curves into it, taking care not to chip or shatter the material. He’s found a reliable way of doing this with a CNC mill and is sharing his methods.

The material he’s working with is a cold mirror; it reflects visible light while allowing infrared light to pass through. He had to custom order it, breakage is not acceptable. [Ben] explains that the biggest risk when milling glass is the clamping method used. He built his own jig and uses shims, rather than clamps, to secure the material along the X and Y axes. It is held down on the Z axis using a bar of acrylic spanning from one side to the other with rubber feet on the bottom.

A diamond burr cutter does the work, spinning at 3000 RPM. [Ben] recommends moving the head at the slowest rate possible in order to give the cutter time to do its work. And of course the material needs to be kept cool by pumping cutting fluid across it. As he shows in the video after the break, what you get is a piece of glass that comes out with clean and smooth edges.

In case we’ve sparked your curiosity, this mirror will be used during an MRI scan. The patient looks at a monitor reflected in the mirror at a 45 degree angle. At the same time, an infrared camera records the patient from the other side of the mirror to monitor where they are looking.

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LEGO Mill Produces Sculpted Models With Fantastic Resolution

August 20, 2011 by Mike Szczys 19 Comments

[Arthur Sacek] has really got something with the 3D Mill he built entirely from LEGO pieces. As you can see, it uses NXT parts to control the cutter head along three axes. The drill bit that acts as the mill’s cutting head is not a LEGO part, but that’s [Arthur’s] only transgression.

The demo sculpture seen above was cut into a block of floral foam. The model was processed by Autodesk Softimage before being fed into the mill, where it took about two and half hours to complete the job. The foam comes out still in block form looking like a piece of outdoor carpeting. That’s because there’s no debris removal during the milling process. But hit it with the shopvac and you’ll reveal a physical model with surprising detail. We don’t think it comes close to the light-cured resin printing we’ve seen, but it would be a great asset if you’re doing some mold making.

Don’t miss [Arthur’s] video of the milling process after the break.

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Robotic Artist Listens To Your Criticism

August 18, 2011 by Brian Benchoff 8 Comments

[Ben Grosser] built an interactive painting robot that’s pretty far removed from the LED and Arduino builds we usually see. The robot is adapted from one of the many CNC routers we’ve featured over the years. The control system is written in Python and uses genetic algorithms and a microphone to decide what to paint next.

Robot artists have been around for decades now. When [Harold Cohen] exhibited his robotic artist AARON, gallery patrons lined up to watch a robot paint. The paintings were originally just a monochrome line drawing that was later colored in by [Cohen]. [Ben] made his robot paint directly onto canvas with oil paints, so there’s no question of what the computer intends the final product to be.

[Ben] came up with a really neat build, but we’re wondering about having this robot artist on display inside a cavernous exhibition hall. Surely the echos from the servos and stepper motors would be picked up by the mic and interpreted by the painting algorithm. Barring some control systems, it would probably be the robot’s commentary on its own decent into madness.

Check out a video of the robot in action after the break, followed by a violin/robot duet the shows how the audio is interpreted.

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Etch-a-Sketch Automatically Draws A Tribute To Hack A Day

August 5, 2011 by Mike Nathan 8 Comments

automated_etch_a_sketch_hack_a_day_logo

We have seen quite a few automated Etch-a-Sketch machines in our time, but when [Jason] wrote in to share his take on the subject, it came with a nice bribe attached. We are vain. It’s not something we are proud of, but when it comes to seeing the Hack a Day logo drawn out by a robot, consider us sold.

[Jason] has several CNC router builds under his belt, and thought it would be fun to automate his Etch-a-Sketch, a toy he loved as a child. He cut some gears and a face plate for the toy with his new CNC machine, then got busy programming his Propeller microcontroller to do his bidding.

A piece CNC software handles the conversion of a bitmap image to an outline, which is then converted to a CNC cutting path. The cutting path is translated into x/y coordinates by a bit of C++ code, before being fed into the microcontroller, which is running a small SPIN application he calls RoboSketch. The Propeller takes care of the rest, quickly drawing the image or pattern to the Etch-a-Sketch.

Continue reading if you would like to see a video of [Jason’s] tribute to Hack a Day, and don’t miss some of our previous automated Etch-a-Sketch coverage if this is something on your to-do list.

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RepRap Voyeurism

August 3, 2011 by Mike Szczys 13 Comments

Hey everybody, [Nbitwonder] is building his own RepRap 3D printer. What’s special about that? Well, not much and and lot all at the same time. The art of building a self-replicating 3d printer still has a lot to do with luck and forum-crawling to make all of the decisions that go into this complicated project.

Back in March [Nbitwonder] did a collaborative project over at Thingiverse and scored himself a set of printed parts from a guy who already has one of these printers. He then order a set of the non-printable hardware and has since been assembling it. If you’re interested but haven’t already taken the plunge, there’s enough pictures and information in this set of posts to satisfy your craving… for now.

We say this build is an art because it goes beyond just plunking the pieces together. Take the print head, for instance. Instead of going with the extruder that is considered the default for a Mendel build, [Nbitwonder] is working on a variation called Greg’s Hinged Accessible Extruder. We can’t wait until the hardware assembly is done, because it’s the calibration that really interests us.