Cleaner Laser Cutting With A 3D-Printed Nozzle

November 25, 2020 by Donald Papp 24 Comments

[Nervous System] does a lot of laser cutting, and [Jesse] shared a fascinating experimental improvement to their laser cutter that consists of a 3D-printed nozzle for cleaner cuts. You can see the results for yourself above, where the difference between the two cuts is striking.

[Jesse]’s modification doesn’t affect the laser beam itself; it is an improvement on the air assist, which is the name for a constant stream of air that blows away smoke and debris as the laser burns and vaporizes material. An efficient air assist is one of the keys to getting nice clean laser cuts, but [Jesse] points out that a good quality air assist isn’t just about how hard the air blows, it’s also about how smoothly it does so. A turbulent air assist can make scorch marks worse, not better.

3D-printed nozzle to promote laminar air flow on the left, stock nozzle on the right.

As an experiment to improve the quality of the air flowing out the laser nozzle, [Jesse] researched ways to avoid turbulence by creating laminar flow. Laminar flow is the quality of a liquid having layers flowing past one another with little or no mixing. One way to do this is to force liquid through individual, parallel channels as it progresses towards a sharply-defined exit nozzle. While [Jesse] found no reference designs of laminar flow nozzles for air assists, there were definitely resources on making laminar flow nozzles for water. It turns out that interest in such a nozzle exists mainly as a means of modifying Lonnie Johnson’s brilliant invention, the Super Soaker.

Working from such a design, [Jesse] created a custom nozzle to help promote laminar flow. Sadly, a laser cutter head carries design constraints that make some compromises unavoidable; one is limited space, and another is the need to keep the laser’s path unobstructed. Still, after 3D printing it in rigid heat-resistant resin, [Jesse] found a dramatic improvement in the feel of the air exiting the nozzle. Some test cuts confirmed a difference in performance, which results in a noticeably cleaner kerf without scorching around the edges.

One of the things [Nervous System] does is make their own custom puzzles, so any improvement to laser cutting helps reliability and quality. When production is involved, just about everything matters; a lesson [Nervous System] shared when they discussed making the best plywood for creating their puzzles.

DualShock Flight Simulator Yoke

November 4, 2020 by Danie Conradie 6 Comments

Aircraft control interfaces can be divided into stick or yoke, with the stick being more popular for flight simulators. [Akaki Kuumeri] has been designing some ingenious 3D printed adaptors for game console controllers, and his latest build is a yoke adaptor for the PlayStation DualShock Controller.

Like his previous joystick/throttle combination, this yoke makes use of a series of ball and socket links to convert the yoke’s push/pull and rotation motion into the appropriate inputs on the controller’s thumbs sticks. All the components are 3D printed except for rubber bands to provide spring tension. On the sliding contact surfaces between the different components, [Akaki] specifically designed the parts to slide along the grain (layer lines) to allow for smooth motion without resorting to bearings.

If you want an absolute minimalist yoke, tape some potentiometers to a desk drawer. Or you can go to the other end of the scale and build a complete cockpit. With the arrival of Microsoft Flight Simulator 2020, we’ll be seeing a lot of controller builds.

Flies Like A Quadcopter, But This Drone Design Has Only One Propeller

November 2, 2020 by Danie Conradie 35 Comments

When mentioning drones, most people automatically think of fixed-wing designs like the military Reaper UAV or of small quadcopters. However, thanks in large part to modern electronics, motors, and open-source control systems, it is possible to build them in a variety of shapes and sizes. [Benjamin Prescher] is working on the second version of his single rotor Ball-Drone, which uses four servo-actuated fins for control.

The first version of the ball drone flew but was barely controllable and had a tendency to tip over. After a bit of research, he found that he had fallen victim to the drone pendulum fallacy by mounting the heavy components below the propeller and control fins. Initially, he also used conventional fin control that caused the servos to jitter due to high torque loading. By changing to grid fins, the actuation torque was reduced, eliminating the servo jitter.

Mk2 corrected the pendulum problem by moving most of the components to the top of the drone. The 3D printed frame (available on Thingiverse) was also dramatically changed and simplified to reduce weight. Although [Benjamin] designed a custom flight controller with custom control software, the latest parts list contains an off-the-shelf flight controller. He mentions that he had started working with Betaflight. The most complex part of a drone is not the mechanics or even the electronics, but the control software. Thanks to open source projects like Betaflight and Ardupilot, you don’t need to write control software from scratch to get something in the air.

The ball drone seems well suited to an indoor environment, but we’re not sure if it has any real advantages over a quadcopter with ducted propellers. Servos are cheaper than motors and ESCs, so there might be a small cost saving. Drop your thoughts on the advantages/disadvantages in the comments below. Continue reading “Flies Like A Quadcopter, But This Drone Design Has Only One Propeller” →

Big Workshop Clock Is 3D Printing Done Right

November 1, 2020 by Lewin Day 7 Comments

Time is something uniquely important to humans, and they remain the only creatures on the planet to build devices to regularly track its progress. [Ivan Miranda] is one such creature, and built a giant 7-segment clock for his workshop that really ties the room together.

The clock is a testament to [Ivan]’s design skills in the 3D printed space. Taking advantage of his large format printer, each segment consists of a front panel, large single-piece diffuser, LED carrier, and backing plate. There are plenty of nice touches, from the interlocking ridges between each digit, to integral printed arrows on the inside that guide installation of the LED strips. Fit and finish approaches the level of a commercial product, a reward for [Ivan]’s years of practice in the field.

Electronically, an ESP8266 runs the show, synchronizing the time over its in-built WiFi connection. Each segment contains 9 WS2812B LEDs, wired up in a single long strip that’s addressed by the microcontroller. This means that the segments can be lit up to any color of the rainbow, though [Ivan] is a man who best appreciates the look of classic red.

[Ivan]’s long been a proponent of big 3D-printed builds — his tank-tracked electric skateboard is a particularly good example. Video after the break.

Continue reading “Big Workshop Clock Is 3D Printing Done Right” →

Complete Flight Sim Controller Set With 3D Printing And Hall-Effect Sensors.

October 26, 2020 by Danie Conradie 17 Comments

[Tom Stanton] has been playing Microsoft Flight Simulator a lot recently, and decided his old desktop joystick needed an upgrade. Instead of just replacing it with a newer commercial model, he built a complete controller system with a long joystick that pivots at floor level, integrated rudder pedals and a throttle box. You can see it in action after the break.

The throw of the joystick is limited by [Tom]’s legs and chair, with only 12° of travel in either axis, which is too small to allow for high resolution with a potentiometer. Instead, he used hall effect sensors and a square magnet for each axis, which gives good resolution over a small throw angle. The pivot that couples the two rudder pedals also makes use of a hall effect sensor, but needs more travel. To increase the size of the magnetic field, [Tom] mounted two magnets on either side of the sensor with their poles aligned. To center the rudder pedals and joystick, a couple of long tension springs were added.

The joystick (left) and rudder pedals (right) magnet configurations with a hall effect sensor.

A normal potentiometer was used in the throttle lever, and [Tom] also added a number of additional toggle switches and buttons for custom functions. The frame of the system is built with T-slot extrusions, so components can quickly moved to fit a specific user, and adjust the preload on the centering springs. All the electronic components are wired to an Arduino Micro, and thanks to a joystick library, the code is very simple.

At a total build cost of £212/$275 it’s certainly not what anyone would call cheap, but it’s less than what you’d pay for a commercial offering. All the design files and build details are linked in the second video if you want to build your own.

The flight sim controller builds are coming in thick and fast with the release of the latest MS Flight Simulator. With 3D printing you can augment an Xbox controller with a joystick and throttle, or just use tape and a few electronic components turn a desk drawer into a flight yoke.

A Linear Stencil Clock Built For Quiet Operation

October 22, 2020 by Dan Maloney 19 Comments

We around the Hackaday shop never get tired of seeing new ways to mark the passage of time. Hackers come up with all manner of interesting timekeeping modalities using every imaginable material and method of moving the mechanism once per whatever minimum time unit the hacker chooses to mark.

But honestly, there are only so many ways to make a clock, and while we’re bound to see some repeats, it’s still nice to go over old ground with a fresh approach. Take this linear sliding stencil clock for instance. [Luuk Esselbrugge] has included some cool design elements that bear a closer look. The video below shows that the display is made up of four separate stepper motors, each driving a vertical stencil via a rack-and-pinion mechanism. There a simple microswitch for homing the display, and a Neopixel for lighting things up.

The video below shows that the stencils move very, very slowly; [Luuk] says that this is to keep the steppers as quiet as possible. Still, this means that some time changes take more than a minute to accomplish, which is a minor problem. The Neopixel also doesn’t quite light up just one digit, which should be a pretty easy fix for version 2. Still, even with these issues, we like the stately movements of this clock, and appreciate [Luuk]’s attempts to make it easier to live with.

Don’t let the number of clocks you see on these pages dissuade you from trying something new, or from putting your twist on an old design. Start with fridge magnets, an old oscilloscope, or even a bevy of steel balls, and let your imagination run wild. Just make sure to tell us all about it when you’re done.

Continue reading “A Linear Stencil Clock Built For Quiet Operation” →

PyBot Is A 3D Printed SCARA Arm For The Masses

October 19, 2020 by Tom Nardi 10 Comments

We’ve all seen videos of blisteringly fast SCARA arms working on assembly lines, and more than a few of us have fantasied about having that same kind of technology for the home shop. Unfortunately, while the prices for things like 3D printers and oscilloscopes have dropped lower than what many would have believed possible a decade ago, high-performance robotics are still too pricey for the home player.

Unless of course, you’re willing to build it yourself. The PyBot designed by [jjRobots] is an open source robotic arm that should be well within the means of the average hardware hacker. One could argue that this is a project made entirely possible by desktop 3D printing; as not only are most of the structural components printed, but most of the mechanical elements are common 3D printer parts. Smooth rods, linear bearings, lead screws, and NEMA 17 motors are all exceptionally cheap these days thanks to the innumerable 3D printer kits that make use of them.

A custom control board keeps the wiring tight.

Those who’ve researched similar projects might notice that the design of this arm has clearly been influenced by the Mostly Printed SCARA (MPSCARA). But while that robot was designed to carry an extruder and act as a 3D printer, [jjRobots] intends for the PyBot to be more of a general purpose platform. By default it features a simple gripper, but that can easily be changed out for whatever tool or gadget you have in mind.

In the base of the arm is a custom control board that combines an Arduino M0, an ESP8266, and a trio of stepper motor drivers. But if you wanted to build your own version from the parts bin, you could certainly wire up all the principle components manually. As the name implies, the PyBot is controlled by Python tools running on the computer, so it should be relatively easy to get this capable arm to do your bidding.

We’ve seen some impressive 3D printed robotic arms over the years, but the simplicity of the PyBot is particularly compelling. This looks like something that you could reasonably assemble and program over a weekend or two, and then put to work in your ad-hoc PPE factory.