A sliced digital file of a marker light enclosure. Background is a white and grey grid and object itself is a series of print path lines in red, orange, and green.

3D Printing Hard-To-Find Vintage Vehicle Parts

October 7, 2022 by Navarre Bartz 52 Comments

When I was growing up, my dad and I restored classic cars. Combing junkyards for the pieces we needed was a mixture of interesting and frustrating since there was always something you couldn’t find no matter how long you looked. [Emily Velasco] was frustrated by the high price of parts even when she was able to find them, so she decided to print them herself. She wrote an excellent tutorial about designing and 3D printing replica parts if you find yourself in a similar situation.

All four marker lights on [Velasco]’s 1982 Toyota pickup were on their way to plastic dust, and a full set would run her $160. Instead of shelling out a ton of cash for some tiny parts, she set out to replicate the marker lamps with her 3D printer. Using a cheap marker lamp replacement for a more popular model of pickup as a template, she was able to replace her marker lamps at a fraction of the cost of the options she found online. Continue reading “3D Printing Hard-To-Find Vintage Vehicle Parts” →

With A Little Heat, Printed Parts Handle Vacuum Duty

September 13, 2022 by Tom Nardi 40 Comments

We don’t have to tell the average Hackaday reader that desktop 3D printing has been transformative for our community, but what might not be as obvious is the impact the technology has had on the scientific community. As explained in Thermal Post-Processing of 3D Printed Polypropylene Parts for
Vacuum Systems by [Pierce Mayville], [Aliaksei Petsiuk], and [Joshua Pearce], the use of printed plastic parts, especially when based on open source designs, can lead to huge cost reductions in the production of scientific hardware.

More specifically, the authors wanted to examine the use of 3D printing components to be used in a vacuum. Parts produced with filament-based printers tend to be porous, and as such, are not suitable for fittings or adapters which need to be pumped down to below one atmosphere. The paper goes on to explain that there are coatings that can be used to seal the printed parts, but that they can outgas at negative pressures.

The solution proposed by the team is exceptionally simple: after printing their desired parts in polypropylene on a Lulzbot Taz 6, they simply hit them with a standard consumer heat gun. With the temperature set at ~400 °C, it took a little under a minute for the surface of take on a glossy appearance — the result reminds us of an ABS print smoothed with acetone vapor.

As the part is heated, the surface texture visibly changes. The smoothed parts performed far better in vacuum testing.

In addition to the heat treatment, the team also experimented with increasing degrees of infill overlap in the slicer settings. The end result is that parts printed with a high overlap and then heat treated were able to reliably handle pressures as low as 0.4 mTorr. While the paper admits that manually cooking your printed parts with a heat gun isn’t exactly the ideal solution for producing vacuum-capable components, it’s certainly a promising start and deserves further study.

Custom Printed Knobs In Just A Few Lines Of Code

August 30, 2022 by Tom Nardi 25 Comments

While not everyone is necessarily onboard for the CAD-via-code principle behind OpenSCAD, there’s no denying the software lends itself particularly well to parametric designs. Using a few choice variables, it’s possible to make a model in OpenSCAD that can be easily tweaked by other users — even if they have zero prior experience with CAD.

Take for example this parametric-knob-maker written by [aminGhafoory]. The code clocks in at less than 100 lines, but if you’re looking to spin up your own version, all you really need to pay attention to are the clearly labeled variables up at the top. Just plug in your desired diameter and height, fiddle around a bit with the values that get fed into the grip generating function, and hit F7 to export it to an STL ready for printing.

Now admittedly, all the knobs generated with this code will look more or less the same. But that’s the beauty of open source, should you want to print out some wild looking knobs, you can at least use this code as a basis to build on. With the core functionality in place, you just need to concern yourself with writing a new function to generate a grip texture more to your liking.

Of course, if you want to make your OpenSCAD designs even easier for others to modify, you’ll want to look into its impressive customizer capability which replaces manually edited variables with friendly sliders and text input boxes. Projects like the Ultimate Box Maker we looked at back in 2018 are an excellent example of how powerful OpenSCAD can be if you give your design the proper forethought.

Up Your Desk Toy Game With This 3D Printed Escalator

August 9, 2022 by Tom Nardi 21 Comments

Let’s be real, nobody needs a tiny motorized escalator for their desk. But now that you’ve seen it, can you really say you don’t want one of your own? The design comes our way from [AlexY], and is actually the logical evolution of a manually-operated version released previously. But for our money (and 3D printing time), we’d definitely go with this new motorized variant.

While the core mechanism is largely the same, the powered unit uses a N20 geared motor and an 18650 cell. There’s no fancy motor controller here — just flip the switch and you’ve got 30 RPMs worth of stair-steppin’ action. When you’ve run the cell down, and you will, there’s an onboard TP4056 charging module to keep the good times rolling.

[AlexY] hasn’t had a chance to document the build process for the motorized version of the escalator, but as most of the parts are compatible with the manual version, you should be able to figure it out by referencing the earlier assembly guide.

Hot squirted plastic not your thing? We’ve previously seen a wooden escalator designed to keep a Slinky in motion for as long as it takes for you to realize you could be using your skills for something more constructive.

Continue reading “Up Your Desk Toy Game With This 3D Printed Escalator” →

Build Your Own 3D Printed Bluetooth Headphones

August 5, 2022 by Tom Nardi 18 Comments

A few years back, [Shannon Ley] wondered how hard it would be to build a pair of Bluetooth headphones from scratch. Today, we have our answer. The Homebrew Headphones website is devoted to just one thing: explaining how you can use common components and some 3D printed parts to build an impressively comprehensive pair of wireless headphones for around $50 USD.

The headphones pair a CSR8645 Bluetooth audio receiver with a TP4056 USB-C charging module, a 500 mAh LiPo pouch battery, a pair of Dayton Audio CE38MB-32 drivers, and replacement ear covers designed for the Bose QuietComfort QC15. Some perfboard, a couple buttons, a resistor, and an LED round out the parts list.

All of the components fit nicely into the meticulously designed 3D printed frame, and assembly is made as simple as possible thanks to an excellent step-by-step guide. It’s all so well documented that anyone with even basic soldering experience should be able to piece it together without too much fuss.

Of course, these aren’t the first 3D printed headphones we’ve ever seen. But the quality of the documentation and attention to detail really make these stand out.

DIY Retrograde Clock Is 3D Printed

July 28, 2022 by Lewin Day 3 Comments

Retrograde clocks are unique, in that they eschew the normal fully-circular movement for the hands. Instead, the hands merely sweep out a segment of a circular arc, before jumping back to their start position to begin again. They’re pretty rare to find, but [Jamie Matthews] decided he had to have one. Thusly, he elected to build his own!

For his build, [Jamie] started with a regular off-the-shelf clock movement you might find in any hobbyist clock build. From there, he affixed his own witches’ brew of racks and gears to the output in order to create the desired semi-circular mechanism. The arcane mechanism enables the clock to tell time over roughly a 180-degree arc.

It’s relatively simple to make one of your own, too. The parts are all readily 3D printable, with [Jamie] reporting it took less than 8 meters of filament to produce the geartrain for his build. You can even print the clock face if you don’t want to CNC cut it out of acrylic.

Overall, it’s a fun look at an often-forgotten part of our horological history. Desktop 3D printing really does enable the creation of some exciting, different clock designs. Video after the break.

Continue reading “DIY Retrograde Clock Is 3D Printed” →

Skip The Shipping, Print Your Own Cable Chains

April 12, 2022 by Lewin Day 11 Comments

CNC machines and 3D printers tend to have plenty of cabling which must be neatly managed while the machine moves. If not properly taken care of, wires can easily end up tangled in the moving bits leading to a dead machine at best, and some kind of raucous fire at worst. [Nikodem Bartnik] decided to create his own cable chains for his CNC build to keep everything in check.

The benefit of cable chains is that they stop cables splaying everywhere while still allowing them to move as needed with the axes of the machine. [Nikodem] created 20mm and 40mm chains for his build, affixed into the aluminium extrusion with bolts and T-nuts for easy assembly. The chains are assembled by hand, with 3D printed clips that hammer in place to hold the cables inside once inserted.

Of course, there’s nothing stopping you from buying cable chains off the shelf. But if you don’t want to wait for shipping in this era of cursed supply chains, or you want a cable chain you can customize to perfectly suit your machine, making your own could be the way to go.

Continue reading “Skip The Shipping, Print Your Own Cable Chains” →