Bringing High Temperature 3D Printing To The Masses

October 28, 2020 by Tom Nardi 77 Comments

Despite the impressive variety of thermoplastics that can be printed on consumer-level desktop 3D printers, the most commonly used filament is polylactic acid (PLA). That’s because it’s not only the cheapest material available, but also the easiest to work with. PLA can be extruded at temperatures as low as 180 °C, and it’s possible to get good results even without a heated bed. The downside is that objects printed in PLA tend to be somewhat brittle and have a low heat tolerance. It’s a fine plastic for prototyping and light duty projects, but it won’t take long for many users to outgrow its capabilities.

The next step up is usually polyethylene terephthalate glycol (PETG). This material isn’t much more difficult to work with than PLA, but is more durable, can handle higher temperatures, and in general is better suited for mechanical parts. If you need greater durability or higher heat tolerance than PETG offers, you could move on to something like acrylonitrile butadiene styrene (ABS), polycarbonate (PC), or nylon. But this is where things start to get tricky. Not only are the extrusion temperatures of these materials greater than 250 °C, but an enclosed print chamber is generally recommended for best results. That puts them on the upper end of what the hobbyist community is generally capable of working with.

Industrial 3D printers like the Apium P220 start at $30,000.

But high-end industrial 3D printers can use even stronger plastics such as polyetherimide (PEI) or members of the polyaryletherketone family (PAEK, PEEK, PEKK). Parts made from these materials are especially desirable for aerospace applications, as they can replace metal components while being substantially lighter.

These plastics must be extruded at temperatures approaching 400 °C, and a sealed build chamber kept at >100 °C for the duration of the print is an absolute necessity. The purchase price for a commercial printer with these capabilities is in the tens of thousands even on the low end, with some models priced well into the six figure range.

Of course there was a time, not quite so long ago, where the same could have been said of 3D printers in general. Machines that were once the sole domain of exceptionally well funded R&D labs now sit on the workbenches of hackers and makers all over the world. While it’s hard to say if we’ll see the same race to the bottom for high temperature 3D printers, the first steps towards democratizing the technology are already being made.

Continue reading “Bringing High Temperature 3D Printing To The Masses” →

What’s In A USB-C Connector?

October 27, 2020 by Jenny List 30 Comments

Anyone who’s ever put together a bill-of-materials for an electronic device will be familiar with the process of scouring supplier catalogs and data sheets for the best choice of components. The trick is to score the best combination of price and performance for the final product, and for those unused to the process, there are always seemingly identical products with an astonishingly wide variety of prices. It’s a topic [Timon] explores in a Twitter thread, examining a 20-cent in quantity of 100 USB-C socket alongside one that costs only 5 cents, and his teardown provides a fascinating insight into their manufacture.

The parts look so nearly identical that while it’s possible to differentiate between them visually, it’s near impossible to work out which was the cheaper. Some tiny features such as a crack in a metal fold or a bit less plating on the contacts emerge, but even then it’s no guide to the quality as they don’t appear on the same part. It’s only when the metal shell is removed to expose the underlying plastic moulding that more clues emerge, as one moulding is more complex than the other. The more complex moulding provides a better and more reliable fit at the expense of a much more costly moulding process, so at last we can not only identify the more expensive part but also see where the extra cash has gone. It’s a subtle thing, but one that could make a huge difference to the performance of the final assembly and which makes for a fascinating expose for electronic design engineers.

If connectors are your thing, there’s a wealth of fascinating information in their history.

Plastic Strips Protect Ball Screws On This Homebrew CNC Router

October 26, 2020 by Dan Maloney 17 Comments

It’s a fact of life for CNC router owners — swarf. Whether it’s the fine dust from a sheet of MDF or nice fat chips from a piece of aluminum, the debris your tool creates gets everywhere. You can try to control it at its source, but swarf always finds a way to escape and cause problems.

Unwilling to deal with the accumulation of chips in the expensive ball screws of his homemade CNC router, [Nikodem Bartnik] took matters into his own hands and created these DIY telescopic ball screw covers. Yes, commercial ball screw covers are available, but they are targeted at professional machines, and so are not only too large for a homebrew machine like his but also priced for pro budgets. So [Nikodem] recreated their basic design: strips of thin material wound into a tight spring that forms a tube that can extend and retract. The first prototypes were from paper, which worked but proved to have too much friction. Version 2 was made from sheets of polyester film, slippery enough to get the job done and as a bonus, transparent. They look pretty sharp, and as you can see in the video below, seem to perform well.

It’s nice to see a build progress to the point where details like this can be addressed. We’ve been following [Nikodem]’s CNC build for years now, and it really has come a long way.

Continue reading “Plastic Strips Protect Ball Screws On This Homebrew CNC Router” →

Improved Flexible Build Plate For SLA Is Ready To Rock

October 26, 2020 by Donald Papp 25 Comments

The Elegoo Mars is an affordable SLA (resin-based) 3D printer, and there are probably few that have seen more mods and experimentation than [Jan Mrázek]’s machine. The final design of his DIY flexible build plate is a refinement of his original proof of concept, which proved a flexible build platform can be every bit as useful on an SLA printer as it is for FDM; instead of chiseling parts off a rigid build platform, simply pop the flexible steel sheet off the magnetic base and flex it slightly for a much easier part removal process. His original design worked, but had a few rough edges that have since been ironed out.

We love how [Jan] walks through all of the design elements and explains what worked and what didn’t. For example, originally he used a galvanized steel sheet which was easy enough to work with, but ended up not being a viable choice because once it’s bent, it stays bent. Spring steel is a much better material for a flexible build platform, but is harder for a hobbyist to cut.

Fortunately, it’s a simple job for any metal fabrication shop and [Jan] got a variety of thicknesses cut very cheaply. It turns out that the sweet spot is 0.3 mm (although 0.2 mm is a better choice for particularly fragile parts.) [Jan] also suggests cutting the sheet a few millimeters larger than the build platform; it’s much easier to peel the sheet off the magnetic base when one can get a fingertip under an edge, after all.

The magnetic base that the steel sheet sticks to is very simple: [Jan] converted a stock build platform by mounting an array of 20 x 20 x 1 mm magnets with 3M adhesive mounting tape. He was worried that resin might seep in between the magnets and cause a problem, perhaps even interfering with the adhesive; but so far it seems to be working very well. Resin is viscous enough that it never penetrates far into the gaps, and no effect on the adhesive has been observed so far.

Watch how easily parts are removed in the short video embedded below, in which [Jan] demonstrates his latest platform design.

Continue reading “Improved Flexible Build Plate For SLA Is Ready To Rock” →

Pulse Oximetry Sensor Judges Your Coffee Roast

October 22, 2020 by Donald Papp 24 Comments

Breakout board for the MAX30101, which [Zach] used as the basis of his roast gauge. The sensor is at the top edge of the board.

Parts designed and marketed for a specific application can nevertheless still be useful in other ways, and whenever that happens, it’s probably the start of a pretty good hack. Using a sensor for something other than its intended purpose is exactly what [Zach Halvorson] did to make the Roast Vision device, which uses the MAX30101, a sealed optical sensor intended mainly for pulse oximetry and heart-rate monitoring.

[Zach] is instead using that sensor to measure the roast level of coffee beans, and assign a consistent number from 0 to 35 to represent everything from Very Dark to Very Light. Measuring a bean’s roast level is important to any roaster seeking accuracy and consistency, but when [Zach] found that commercial roast gauges could easily cost over a thousand dollars, he was sure he could do better.

[Zach] settled on using a Sparkfun MAX30101 breakout board to develop his device, and Sparkfun shared an informative blog post that demonstrates how making hardware and tools more accessible can help innovative ideas flourish. The Roast Vision device has a 3D printed enclosure, and a simple top-loading design with an integrated sample cup makes it easy to use. One simply puts about a teaspoon of finely-ground coffee into the sample cup, and the unit provides a measurement in a couple of seconds. Fortunately the sensor works just fine though an acrylic window which means the device can be sealed; a handy feature for a tool that will spend a lot of time around ground coffee.

The joys of fresh roasted coffee is something that is perfectly accessible to those making small batches at home. There are commercial options for small roasters of course, but should you wish to go the DIY route, check out our own Elliot Williams’ guide on making a low-cost DIY roaster.

New Raspberry Pi 4 Compute Module: So Long SO-DIMM, Hello PCIe!

October 19, 2020 by Elliot Williams 151 Comments

The brand new Raspberry Pi Compute Module 4 (CM4) was just released! Surprised? Nope, and we’re not either — the Raspberry Pi Foundation had hinted that it was going to release a compute module for the 4-series for a long while.

The form factor got a total overhaul, but there’s bigger changes in this little beastie than are visible at first glance, and we’re going to walk you through most of them. The foremost bonuses are the easy implementation of PCIe and NVMe, making it possible to get data in and out of SSDs ridiculously fast. Combined with optional WiFi/Bluetooth and easily designed Gigabit Ethernet, the CM4 is a connectivity monster.

One of the classic want-to-build-it-with-a-Pi projects is the ultra-fast home NAS. The CM4 makes this finally possible.

If you don’t know the compute modules, they are stripped-down versions of what you probably think of as a Raspberry Pi, which is officially known as the “Model B” form-factor. Aimed at commercial applications, the compute modules lack many of the creature comforts of their bigger siblings, but they trade those for flexibility in design and allow for some extra functionality.

The compute modules aren’t exactly beginner friendly, but we’re positively impressed by how far Team Raspberry has been able to make this module accessible to the intermediate hacker. Most of this is down to the open design of the IO Breakout board that also got released today. With completely open KiCAD design files, if you can edit and order a PCB, and then reflow-solder what arrives in the mail, you can design for the CM4. The benefit is a lighter, cheaper, and yet significantly more customizable platform that packs the power of the Raspberry Pi 4 into a low-profile 40 mm x 55 mm package.

So let’s see what’s new, and then look a little bit into what is necessary to incorporate a compute module into your own design.

Continue reading “New Raspberry Pi 4 Compute Module: So Long SO-DIMM, Hello PCIe!” →

Spare Parts Express

October 17, 2020 by Elliot Williams 33 Comments

I’ve got spare parts, and I cannot lie.

This week I’m sending out two care packages to friends and coworkers because I’ve got too many hackables on hand, and not enough time to hack them all. One is a funky keyboard, and the other is an FPGA dev board, but that’s not the point. The point is that the world is too interesting, and many of us have more projects piled up in the to-do box, with associated gear, than we’ll ever have time to complete.

Back in the before-times, we would meet up, talk about our ongoing hacks, and invariably someone would say “oh you need an X, I’ve got half a box of them” and send you one. Or maybe you’d be the one with the extra widgets on hand. I know I’ve happily been in both positions.

Either way, it’s a win for the giver, who gets to take a widget off the widget pile, for the receiver, who doesn’t have to go to the widget store, and for the environment, which has to produce fewer widgets. (My apologies to the widget manufacturers and middlemen.)

This reminded me of Lenore Edman and Windell Oskay’s Great Internet Migratory Box Of Electronics Junk back in the late aughts. Trolling through the wiki was like a trip down memory lane. This box visited my old hackerspace, and then ended up with Bunnie Huang. Good times, good people, good hacker junk! And then there’s our own Brian Benchoff’s Travelling Hacker Box and spinoffs.

These are great and fun projects, but they all end up foundering in one respect: to make sense, the value of goods taken and received has to exceed the cost of the postage, and if you’re only interested in a few things in any given box, that’s a lot of dead weight adding to the shipping cost.

So I was trying to brainstorm a better solution. Some kind of centralized pinboard, where the “have too many h-bridge drivers” folks can hook up with the “need an h-bridge” people? Or is this ad-hoc social network that we already have working out well enough?

What do you think? How can we get the goods to those who want to work on them?