3D Printed Bearings With Filament Rollers

October 9, 2024 by Danie Conradie 24 Comments

Commodity bearings are a a boon for makers who to want something to rotate smoothly, but what if you don’t have one in a pinch? [Cliff] of might have the answer for you, in the form of 3D printed bearings with filament rollers.

With the exception of the raw filament rollers, the inner and outer race, roller cage and cap are all printed. It would also be possible to design some of the components right into a rotating assembly. [Cliff] makes it clear this experiment isn’t about replacing metal bearings — far from it. Instead, it’s an inquiry into how self-sufficient one can be with a FDM 3D printer. That didn’t stop him from torture testing the design to its limits as wheel bearings on an off-road go-cart. The first version wasn’t well supported against axial loads, and ripped apart during some more enthusiastic maneuvers.

[Cliff] improved it with a updated inner race and some 3D printed washers, which held up to 30 minutes of riding with only minimal signs of wear. He also made a slightly more practical 10 mm OD version that fits over an M3 bolt, and all the design files are downloadable for free. Cutting the many pieces of filament to length quickly turned into a chore, so a simple cutting jig is also included.

Let us know in the comments below where you think these would be practical. We’ve covered some other 3D printed bearing that use printed races, as well as a slew bearing that’s completely printed. Continue reading “3D Printed Bearings With Filament Rollers” →

Multi-Material Printing Enables Low Cost Silicone Prototypes

September 4, 2024 by Tom Nardi 9 Comments

While it’s the ideal choice for mass production, injection molding is simply no good for prototyping. The molds are expensive and time-consuming make, so unless you’ve got the funding to burn tens of thousands of dollars on producing new ones each time you make a tweak to your design, they’re the kind of thing you don’t want to have made until you’re absolutely sure everything is dialed in and ready. So how do you get to that point without breaking the bank?

That’s not always an easy question, but if you’re working with silicone parts, the team at OpenAeros thinks they might have a solution for you. As demonstrated through their OpenRespirator project, the team has developed a method of 3D printing single-use molds suitable for large silicone parts that they’re calling Digital-to-Silicone (D2S).

In the video below, [Aaron] and [Jon] explain that they started off by simply printing injection molds in the traditional style. This worked, but the molds can get quite complex, and the time and effort necessary to design and print them wasn’t a great fit for their iterative development cycle. They wanted to be able to do from design to prototype in a day, not a week.

Eventually they realized that if they printed the mold out of a water-soluble filament, they could simplify its design greatly. They’ve documented the design process in detail, but the short version is that you essentially subtract the 3D model of the design you want to produce from a solid shape in your CAD package, and add a few holes for injecting the silicone. Once the silicone has cured, the mold can be dissolved away in warm water to reveal the finished part.

They then took this concept a step further. Thanks to the multi-material capabilities offered by some of the latest 3D printers, it’s possible to print structures within the mold. Once the silicone is injected, these structures can become part of the finished part. For the OpenRespirator, this lets them add PETG stiffening rings around where the filters to snap into the silicone mask body.

Continue reading “Multi-Material Printing Enables Low Cost Silicone Prototypes” →

Custom Polyurethane Belts Made Easy

May 15, 2024 by Lewin Day 13 Comments

If you need to make polyurethane belts in custom lengths, it’s not too hard. You just need to take lengths of flexible polyurethane filament, heat the ends, and join them together. In practice, it’s difficult to get it right by hand. That’s why [JBVCreative] built a 3D printed jig to make it easy.

The jig consists of two printed sliders that mount on a pair of steel rods. Each slider has a screw-down clamp on top. The clamps are used to hold down each end of the polyurethane filament to be joined. Once installed in the jig, the ends of the filament can be heated with a soldering iron or other element. and then gently pushed together. The steel rods simply enable the filament to be constrained linearly so the ends don’t shift during the joining process.

The jig doesn’t produce perfect belts. There’s still a small seam at the join that is larger than the filament’s base diameter. A second jig for trimming the belt to size could be helpful in this regard. Still, it’s a super useful technique for making custom belts. This could be super useful to anyone needing to restore old cassette decks or similar mechanical hardware.

Continue reading “Custom Polyurethane Belts Made Easy” →

Vibratory Rock Tumbler Bounces On Printed Spring

April 4, 2024 by Tom Nardi 26 Comments

If you’re reading Hackaday, there’s a good chance you had a rock tumbler in your younger days. Hell, we’d put odds on a few of you having one rumbling away in the background as you read this. They’re relatively simple contraptions, and a common enough DIY project. But even still, this largely 3D printed rock tumbler from [Fraens] is unique enough to stand out.

To make a basic rock tumbler, all you really need to do is rotate a cylindrical chamber and let physics do its thing. Such contraptions are known as, unsurprisingly, rotary rock tumblers. But what [Fraens] has put together here is a vibratory tumbler, which…well, it vibrates. If this was Rockaday we might go farther down this particular rabbit hole and explain the pros and cons of each machine, but the short version is that vibratory tumblers are more mechanically complex and are generally better suited to fine finish work than rotary tumblers which take a brute force approach that tends to round off the rocks.

Continue reading “Vibratory Rock Tumbler Bounces On Printed Spring” →

The Revolver: A 3D-Printed… Screwdriver!

February 8, 2024 by Al Williams 19 Comments

You know those “What my friends think I do” vs “What I actually do” memes? Well there should be one for 3D printing that highlights what you think you’ll do before buying your first printer vs what you actually wind up printing once you get it!

However, thanks to [Revolver3DPrints] you can fulfill your dream of printing a useful tool that looks like a commercial product, the Revolver two-speed screwdriver. The screwdriver isn’t motorized, but it has an interesting midsection that can be rotated to spin the bit, and you can select between a speed and torque mode.

The Revolver isn’t a solution looking for a problem. The designer noted a few issues with normal screwdrivers. They are hard to get into tight spaces, which was the biggest issue. The Revolver is compact, and since you turn its midsection, you don’t have to have clearance for your hand on the top. The gear ratios allow you to apply more torque without needing a long handle.

As you may have guessed, the internal arrangement is a planetary gear drive. You might consider if you want to print this using resin or FDM printing. You also need some screwdriver bits, some glue, and a few magnets to complete the project. If you prefer to make a motorized screwdriver, we’ve seen that done, too.

Continue reading “The Revolver: A 3D-Printed… Screwdriver!” →

2023 Cyberdeck Challenge: Modular Cyberdeck Creation Kit

August 22, 2023 by Brian McEvoy 3 Comments

We were fortunate to run into [Sp4m] at DEFCON31 and see his Modular Cyberdeck Creation Kit in person. In fact, he was wearing it around the hallways like a rogue decker in search of fellow runners. Holding the unit feels like a serious tool because of its weight, mainly from the battery. Everything hangs from a single-point sling on a metal handle, probably from the cabinetry aisle, and we could move silently and comfortably. The sling is firearm-rated, which is appropriate since he has a printed Weaver rail on top. It just needs a flashlight/laser combo.

[Sp4m] aims to create printable parts that combine any on-hand materials into a usable cyberdeck. In this iteration, he uses a wired Apple keyboard and trackpad he found in the trash, so we have to assume he works in IT. Most of the trackpad is covered, but enough is accessible to scroll and maneuver the mouse, saving almost six inches. The Steam deck is the current head but is removable so that this hardware collection can work for many USB-C tablets without fuss.

The eye-catching white/orange is no accident and may earn it a top spot in the Icebreaker category of the 2023 Cyberdeck Contest. The judges are currently deliberating, so keep an eye out for an announcement about the winners shortly.

Scratch Built Amiga 2000 Stacks Up The Mods

March 8, 2023 by Tom Nardi 8 Comments

Around these parts, we most often associate [Drygol] with his incredible ability to bring damaged or even destroyed vintage computers back to life with a seemingly endless bag of repair and restoration techniques. But this time around, at the request of fellow retro aficionado [MrTrinsic], he was given a special assignment — to not only build a new Amiga 2000 from scratch, but to pack it with so many mods that just physically fitting them into the case would be a challenge in itself.

The final product, dubbed Tesseract, took two and a half years to complete and has been documented over the course of six blog posts. The first step was to get a brand new motherboard, in this case a modern recreation designed by Floppie209, and start populating it with components. With some modifications, the new board slipped neatly into a slick metal case. Unfortunately it quickly became clear some of the mods the duo wanted to install wouldn’t work with the reverse-engineered motherboard. This was around Spring of 2021, which is the last time we checked in on the project. Continue reading “Scratch Built Amiga 2000 Stacks Up The Mods” →