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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The Evolution Of A 3D Printed Off-Road R/C Car

April 9, 2020 by Tom Nardi 13 Comments

For about as long as hackers and makers have been using desktop 3D printers, there have been critics that say the plastic parts they produce aren’t good for much else than toys and decorative pieces. They claim that printed parts are far too fragile to be of any practical use, and are better suited as prototype placeholders until the real parts can be injection molded or milled. Sure. Try telling that to [Engineering Nonsense].

He recently wrote in (as did a few other people, incidentally) to share the latest version of his incredible 3D printed remote control car, and seeing it tearing around in the video after the break, “fragile” certainly isn’t a word we’d use to describe it. Though it didn’t get that way overnight. The Tarmo4 represents a year of development, and as the name suggests, is the fourth version of the design.

We know the purists out there will complain that the car isn’t entirely 3D printed, but honestly, it’s hard to imagine you could get much closer than this. Outside of the electronics, fasteners, tires, and shocks, the Tarmo4 is all plastic. That includes the gearbox and drive shafts. [Engineering Nonsense] even mentions in the video that he’s not happy with the tires he’s found on the market, and that they too will likely get replaced with printed versions in the future.

While the car is certainly an incredible technical achievement, what’s perhaps just as impressive is the community that’s developed around it in such a relatively short time. Towards the end of the video he shows off a number of custom builds based on previous iterations of the Tarmo. We’re sure that interest from the community has played a part in pushing the design forward, and it’s always good to see a one-off project become something bigger. Hopefully we’ll be seeing even more from this passionate community in the near future.

Just like the Open R/C Project, Tarmo proves that 3D printed parts are more than a novelty. If these diminutive powerhouses can run with printed gears and drive shafts, then you shouldn’t have anything to worry about when you run off the parts for your next project.

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The CLUE Tracker Points You To A Target, Using CircuitPython

April 5, 2020 by Donald Papp 2 Comments

The main components are an Adafruit CLUE, Stemma GPS, and a lithium-polymer battery. No soldering required.

[Jay Doscher] shares a quick GPS project he designed and completed over a weekend. The device is called the CLUE Tracker and has simple goals: it shows a user their current location, but also provides a compass heading and distance to a target point. The idea is a little like geocaching, in that a user is pointed to a destination but must find their own way there. There’s a 3D printed enclosure, and as a bonus, there is no soldering required.

The CLUE Tracker uses the Adafruit CLUE board (which is the same size as the BBC micro:bit) and Stemma GPS sensor, with the only other active component being a lithium polymer battery. The software side of the CLUE Tracker uses CircuitPython, and [Jay] has the code and enclosure design available on GitHub.

[Jay] did a nice job of commenting and documenting the code, so this could make a great introductory CircuitPython project. No soldering is required, which makes it a little easier to re-use the parts in other projects later. This helps to offset costs for hackers on a budget.

The fact that a device like this can be an afternoon or weekend project is a testament to the fact that times have never been better for hobbyists when it comes to hardware. CircuitPython is also a fast-growing tool, and projects like this can help make it easy and fun to get started.