Combine Broken Drone Propellers For A Second Spin

May 6, 2020 by Danie Conradie 8 Comments

If you’ve ever flown or watched anyone fly a racing drone for any length of time, you know that crashes are just part of the game and propellers are consumables. [Adam] knows this all to well, decided to experiment with combining multiple broken propellers into one with a 3D printed hub.

A damaged propeller will often have one blade with no damage, still attached to the hub. [Adam] trimmed the damaged parts of a few broken props, and set about designing a 3D printed hub to attach the loose blades together. The hubs were designed let the individual blades to move, and folding out as the motors spin up, similar to the props on many photography drones.

Once [Adam] had the fit of the hubs dialed in, he mounted a motor on a piece of wood and put the reborn propellers through their paces. A few hubs failed in the process, which allowed [Adam] to identify weak points and optimise the design. This sort of rapid testing is what 3D printing truly excels at, allowing test multiple designs quickly instead of spending hours in CAD trying to foresee all the possible problems.

He then built a test drone from parts he had lying around and proceeded with careful flight testing. The hubs were thicker than standard propellers so it limited [Adams] motor choices to ones with longer shafts. Flight testing went surprisingly well, with a hub only failing after [Adam] changed the battery from a 3 cell to a 4 cell and started with some aerobatics. Although this shows that the new props are not suitable for the high forces from racing or aerobatics/freestyle flying, they could probably work quite well for smoother cruising flights. The hubs could also be improved by adding steel pins into the 3D printed shafts, and some carefully balancing the assembled props.

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Quarantine Clock Answers The Important Question

May 5, 2020 by Tom Nardi 20 Comments

For many people, these last few weeks have been quite an adjustment. When the normal routine of work or school is suddenly removed, it’s not unusual for your internal clock to get knocked out of alignment. It might have started with struggling to figure out if it was time for lunch or dinner, but now it’s gotten to the point that even the days are starting to blur together. If it takes more than a few seconds for you to remember whether or not it’s a weekday, [whosdadog] has come up with something that might help you get back on track.

Rather than showing the time of day, this 3D printed clock tells you where you are in the current week. Each day at midnight, the hand will advance to the center of the next day. If you wanted, a slight reworking of the gearing and servo arrangement on the rear of the device could allow it to sweep smoothly through each day. That would give you an idea of your progress through each 24 hour period, but then again, if you don’t even know if it’s morning or night you might be too far gone for this build anyway.

The clock’s servo is driven by a Wemos D1 Mini ESP8266 development board, which naturally means it has access to WiFi and can set itself to the current time (or at least, day) with NTP. All you’ve got to do is put your network information into the Sketch before flashing it to the ESP, and you’re good to go.

Naturally this project is a bit tongue-in-cheek, but we do think the design has practical applications. With a new face and some tweaked code, it could be an easy way to show all sorts of data that doesn’t require a high degree of granularity. Our very own [Elliot Williams] recently built a display to help his young son understand his new at-home schedule which operates on a similar principle.

Take This Cylindrical Coupler Design For A Spin

May 4, 2020 by Tom Nardi 19 Comments

We’re not exactly sure what kind of shenanigans [Conrad Brindle] gets himself into, but apparently it often requires cylindrical couplings to attach 3D printed parts to each other. He found himself designing and redesigning this type of connector so often that he decided to just make a parametric version of it that could be scaled to whatever dimensions are necessary for that particular application.

In the video after the break, [Concrad] explains the concept behind the coupler and how he designed it. Put simply, the tabs inside of the coupler are designed to grab onto each other once the coupler is spun. When he demonstrates the action, you can see that both sides of the coupler are pulled together tightly with a satisfying little snap, but then can be easily removed just by rotating them back in the opposite direction.

The nature of desktop 3D printing means that the female side of the connection requires support when printing, and depending on your printer, that might mean a relatively rough mating surface. [Conrad] notes that you’ll need to experiment a bit to find how small your particular machine can print out the design before things get too gummed up.

We can see how this would be useful for some applications, but if you need a printed joint that can handle a decent amount of torque before giving up the ghost, you might want to look into (mis)using one half of a spider coupling.

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Human-Powered Laser Gun Makes Battery-Free Target Practice

April 26, 2020 by Donald Papp 15 Comments

[Dirk] shared a fascinating project of his that consists of several different parts coming together in a satisfying whole. It’s all about wanting to do target practice, indoors, using a simple red laser dot instead of any sort of projectile. While it’s possible to practice by flashing a red laser pointer and watching where it lands on a paper target, it’s much more rewarding (and objective) to record the hits in some way. This is what led [Dirk] to create human-powered, battery-free laser guns with software to track and display hits. In the image above, red laser hits on the target are detected and displayed on the screen by the shooter.

Right under the thumb is the pivot point for the lever, and that’s also where a geared stepper motor (used as a generator) is housed. Operating the action cranks the motor.

There are several parts to this project and, sadly, the details are a bit incomplete and somewhat scattered around, so we’ll go through the elements one at a time. The first is the guns themselves, and the star of the show is his 3D printed cowboy rifle design. The rifle paints the target with a momentary red laser dot when the trigger is pressed, but that’s not all. [Dirk] appears to have embedded a stepper motor into the lever action, so that working the lever cranks the motor as a generator and stores the small amount of power in a capacitor. Upon pulling the trigger, the capacitor is dumped into the laser (and into a piezo buzzer for a bit of an audio cue, apparently) with just enough juice to create a momentary flash. We wish [Dirk] had provided more details about this part of his build. There are a few more images here, but if you’d like to replicate [Dirk]’s work it looks like you’ll be on your own to some extent.

As for the target end of things, blipping a red dot onto a paper target and using one’s own eyeballs can do the job in a bare minimum sort of way, but [Dirk] went one further. He used Python and OpenCV with a camera to watch for the red dot, capture it, then push an image of the target (with a mark where the impact was detected) to a Chromecast-enabled screen near the shooter. This offers much better feedback and allows for easier scoring. The GitHub repository for the shot detector and target caster is here, and while it could be used on its own to detect any old laser pointer, it really sings when combined with the 3D printed cowboy rifle that doesn’t need batteries.

Not using projectiles in target practice does have some benefits: it’s silent, it’s easy to do safely, there is no need for a backstop, there are no consumables or cleaning, and there is no need to change or patch targets once they get too many holes. Watch it all in action in the video embedded below.

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Getting Your Morning Mix Exactly Right, Every Time

April 17, 2020 by Danie Conradie 8 Comments

In historical times, before the pandemic, most people had to commute to work in the mornings, and breakfast often ended up being a bit rushed. [Elite Worm] is very serious about getting his breakfast mix exactly right, and o shave a bit of time off the prep, he built a 3D printed automatic ingredient dispenser for his breakfast bowl.

[Elite Worm] breakfast consists of four ingredients, that have either a powder or granular consistency. They are held in 3D printed hoppers, with a screw top for refilling and a servo-operated door with a funnel at the bottom. The hoppers need to be shaken to properly dispense the ingredients, so all four are mounted on a bracket that can slide up and down on linear bearings. The shaking is done by a brushed DC motor with a slider-crank mechanism, which moves bracket and hoppers up and down very vigorously. [Elite Worm] notes that the shaking is probably a bit too violent and can make the entire table shake if it isn’t sturdy enough, and reducing the motor RPM might be a good idea. Below the hopper system sits a movable weighing station with a load cell, a custom ATmega328P based control board and a Nextion touch screen display, which allows for various ingredient combinations to be saved. The load cell is used to keep track of the ingredient quantities by weight, as they are dispensed one at a time.

We really like the ingenuity of the build, but personally, we would have swapped out the hopper for something that’s moulded, since all the crevices in 3D printed parts is a perfect place for bacteria to grow and can be tricky to clean properly Continue reading “Getting Your Morning Mix Exactly Right, Every Time” →

This Camera Captures Piezo Inkjet Micro-Drops For DIY Microfluidics

April 15, 2020 by Donald Papp 6 Comments

In microfluidics, there are “drop on demand” instruments to precisely deposit extremely small volumes (pico- or nano-liters) of fluid. These devices are prohibitively expensive, so [Kyle] set out to design a system using hobbyist-level parts for under $1000. As part of this, he has a fascinating use case for a specialized camera: capturing the formation and shape of a micro-drop as it is made.

There are so many different parts to this effort that it’s all worth a read, but the two big design elements come down to:

Making the microdrop using a piezo element
Ensuring the drop is made correctly, and visually troubleshooting

Working prototype. The piezo tube is inside the blue piece at the top. The camera is to the right, and the LED strobe is on the left.

It’s one thing to make an inkjet element in a printer work, but it’s quite another to make a piezoelectric element dispense arbitrary liquids in a controlled, repeatable, and predictable way. Because piezoelectric elements force liquid out with a mechanical motion, different liquids require different drive signals and that kind of experimentation requires a way to see what is going on, hence the need for a drop observation camera.

[Kyle] ended up taking the lens assembly from a cheap USB microscope and mating it to his Korukesu C1 USB Camera with a 3D printed assembly. Another 3D printed enclosure doubles as a lightbox, holding the piezo tube in the center with the LED strobe and camera on opposite sides. The whole assembly had a few false starts, but in the end [Kyle] seems pretty happy with his results. The device is briefly described at a high level here. There are some rough edges, but it’s a working system.

Inkjet technology has been around for a long time (you can see a thirty-plus year old inkjet printer in action here) but it’s worth mentioning that not all inkjet heads are alike. Most inkjet printer heads operate thermally, which means a flash of heat vaporizes some ink to expel a micro-drop. These heads aren’t very suitable for microfluidics because not only do they rely on vaporizing the liquid, but they also don’t work well with anything other than the ink they’re designed for. Piezoelectric print heads are less common, but are more suited to the kind of work [Kyle] is doing.

Don’t Let Your PLA Filament Hang Loose With This 3D-Printed Surfboard

April 13, 2020 by Moritz v. Sivers 8 Comments

People always tend to push the boundaries of what is doable with a 3D printer. This is also true for [AndrewW1977] when he decided to 3D print a full-sized functional surfboard.

With just over nine full days of printing time, 95 individual pieces, and using 3.1 kg of PLA (not counting all the test prints), this is certainly a monumental project. One of the bigger issues [AndrewW1977] had to solve was avoiding air pockets inside the board. Ideally, you would want to end up with only one continuous hollow chamber in order to easily vent all the air inside the board when it heats up. [AndrewW1977] chose to overcome this problem by using zero infill for each individual piece. The pieces were then connected with the help of alignment pins that have a central hole thereby connecting all hollow chambers.

By using a triangular shape, he managed to print all pieces without using supports. After gluing them together the whole board was covered with fiberglass and epoxy resin similar to traditional surfboard building. Unfortunately, due to the current situation with Covid19 [AndrewW1977] remains short of showing us the board in action. In case you have a 3D printer at home and lots of spare time during lockdown, [AndrewW1977] has published all files for his surfboard on Thingiverse.

As [AndrewW1977] points out in the video embedded below other people have already done similar projects. From jet boats to electric hydrofoils it seems that water sports and 3D printing are a perfect match.

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