The Tiniest RetroPie

January 29, 2019 by Bryan Cockfield 15 Comments

The RetroPie project is a software suite for the Raspberry Pi that allows the user to easily play classic video games through emulators. It’s been around for a while now, so it’s relatively trivial to get this set up with a basic controller and video output. That means that the race is on for novel ways of implementing a RetroPie, which [Christian] has taken as a sort of challenge, building the tiniest RetroPie he possibly could.

The constraints he set for himself were to get the project in at under 100 mm. For that he used a Pi Zero loaded with the RetroPie software and paired it with a 1.44″ screen. There’s a tiny LiPo battery hidden in there, as well as a small audio amplifier. Almost everything else is 3D printed including the case, the D-pad, and the buttons. The entire build is available on Thingiverse as well if you’d like to roll out your own.

While this might be the smallest RetroPie we’ve seen, there are still some honorable mentions. There’s one other handheld we’ve seen with more modest dimensions, and another one was crammed into an Altoids tin with a clamshell screen. It’s an exciting time to be alive!

Continue reading “The Tiniest RetroPie” →

Unobtanium Bezels Finally Modeled For 3D Printing

January 19, 2019 by Brian Benchoff 26 Comments

In 1991, Apple released the Quadra line of computers, named after their utilization of the new Motorola 68040 CPU. The Quadra line initially consisted of two models, the Quadra 700 and the Quadra 900. These two models, and the Quadra 950, released as a slight upgrade to the 900, were the peak of performance. You could conceivably load these machines up with 256 Megabytes of RAM, in an era where hard drives hovered around 80 Megabytes. This much RAM would cost as much as a house. These were powerhouses, the first ProTools workstations, and they ran Jurassic Park. If you wanted peak performance in the early 90s, you got a Quadra.

The Quadra 900 and 950 were tower computers, and there were options for floppy, Zip drives, Bernoulli drives, and a CD-ROM drive. They were introduced a little before the ‘multimedia’ hubub, and right now, the plastic bezel for the CD-ROM option is an absurdly expensive piece of plastic. People have paid $150 for an original CD-ROM bezel. Seems like the perfect application of 3D printing, doesn’t it? That’s exactly what [360alaska] over on the 68k Macintosh Liberation Army forms did. The unobtanium bezel can now be sent off to Shapeways.

This project is a continuation of a thread where various forum members shared their .STLs for random bits of Apple plastic, ranging from rubber feet for PowerBooks to the clip-on ‘programmer’s switch’ for the Macintosh SE. The crowning achievement of this community endeavour is the Quadra 950 CD-ROM bezel. There are a few varieties, ranging from one that fits a standard 5 1/4″ drive, to a nearly exact replica of the official Apple offering for their official drive. All the files are there for the downloadin’.

Printing these bezels will be a bit of a challenge for a filament-based printer, but resin printers are getting cheap and Shapeways is always there for you. Painting to match the brominated patina of old plastic is also a challenge, but the forum members have had some success with off-the-shelf spray paints.

Brush With The Power Of 3D Printing

January 16, 2019 by Brian Benchoff 23 Comments

When it comes to 3D printing, functional prints are still few and far between. Sure, you can print a mount for anything, a Raspberry Pi case, but there are few prints out there that are truly useful, and even fewer that are useful while taking advantage of the specific capabilities of a 3D printer.

The Bouldering Brush from Turbo SunShine turns this observation on its head. It’s a useful device for getting the grime, sand, and sweat out of handholds while rock climbing, and it’s entirely 3D printed using manufacturing techniques only 3D printers can do.

If you’re thinking you’ve seen something like this technique before, you’re correct. The Hairy Lion from [_primoz_] on Thingiverse used a fine mesh of bridging to create small fibers of filament emanating from the mane of a lion. While it’s not a gender-neutral print, this is one of the first objects to make it to Thingiverse that truly showcased the sculptural element of many thin fibers of 3D printed filament. With this Bouldering Brush, these fibers become much more useful and even functional. It’s still a great technique, and if you can get your printer set up correctly and the settings correct, this is an awesome print that will easily demonstrate the capabilities of your printer.

Like the Hairy Lion, the Bouldering Brush is two handles that are mostly solid, and fine filaments of extruded plastic connecting these handles. Take the completed print off the bed , cut down the middle of the bristles, and you have a functional, completely 3D printed brush. Just don’t brush your teeth with it.

New Contest: 3D Printed Gears, Pulleys, And Cams

January 16, 2019 by Mike Szczys 40 Comments

One of the killer apps of 3D printers is the ability to make custom gears, transmissions, and mechanisms. But there’s a learning curve. If you haven’t 3D printed your own gearbox or automaton, here’s a great reason to take the plunge. This morning Hackaday launched the 3D Printed Gears, Pulleys, and Cams contest, a challenge to make stuff move using 3D-printed mechanisms.

Adding movement to a project brings it to life. Often times we see projects where moving parts are connected directly to a servo or other motor, but you can do a lot more interesting things by adding some mechanical advantage between the source of the work, and the moving parts. We don’t care if it’s motorized or hand cranked, water powered or driven by the wind, we just want to see what neat things you can accomplish by 3D printing some gears, pulleys, or cams!

No mechanism is too small — if you have never printed gears before and manage to get just two meshing with each other, we want to see it! (And of course no gear is literally too small either — who can print the smallest gearbox as their entry?) Automatons, toys, drive trains, string plotters, useless machines, clockworks, and baubles are all fair game. We want to be inspired by the story of how you design your entry, and what it took to get from filament to functional prototype.

Continue reading “New Contest: 3D Printed Gears, Pulleys, And Cams” →

The Printed Solution To A Handful Of Resistors

January 16, 2019 by Brian Benchoff 44 Comments

Resistors are an odd bunch. Why would you have 1.0 Ω resistors, then a 1.1 Ω resistor, but there’s no resistors in between 4.7 Ω and 5.6 Ω? This is a question that has been asked for decades, but the answer is actually quite simple. Resistors are manufactured according to their tolerance, not their value. By putting twenty four steps on a logarithmic scale, you get values that, when you take into account the tolerance of each resistor, covers all possible values. Need a 5.0 Ω resistor? Take a meter to some 4.7 Ω and 5.6 Ω resistors. You’ll find one eventually.

As with all resistor collections, the real problem is storage. With SMD resistors you can stack your reels in stolen milk crates, but for through hole resistors, you’ll need some bins. [FerriteGiant] over on Thingiverse did just that. It’s a 3D printable enclosure that takes all of your E24 series resistors.

The design of this resistor storage solution is a bit like those old wooden cases full of index cards at that building where you can rent books for free. Or, if you like, a handy plastic small parts bin from Horror Fraught. The difference here is that these small cases are designed for the standard length of through-hole resistors, and each of the bins will hold a small 3D printed plaque telling you the value in each bin.

While this is a print that will take a lot of time — [FerriteGiant] spent 100 hours printing everything and used two kilograms of filament — it’s not like through-hole resistors are going away anytime soon. This is a project that you can build and have for the rest of your life, safely securing all your resistors in a fantastic box for all time.

Making An Ultrasonic Cutter For Post-processing Tiny 3D Prints

January 7, 2019 by Donald Papp 57 Comments

An ultrasonic knife is a blade that vibrates a tiny amount at a high frequency, giving the knife edge minor superpowers. It gets used much like any other blade, but it becomes far easier to cut through troublesome materials like rubber or hard plastics. I was always curious about them, and recently made my own by modifying another tool. It turns out that an ultrasonic scaling tool intended for dental use can fairly easily be turned into a nimble little ultrasonic cutter for fine detail work.

Cheap ultrasonic scaler. The blue disk is for adjusting power. Foot switch not shown.

I originally started thinking about an ultrasonic knife to make removing supports from SLA 3D prints easier. SLA resin prints are made from a smooth, hard plastic and can sometimes require a veritable forest of supports. These supports are normally removed with flush cutters, or torn off if one doesn’t care about appearances, but sometimes the density of supports makes this process awkward, especially on small objects.

I imagined that an ultrasonic blade would make short work of these pesky supports, and for the most part, I was right! It won’t effortlessly cut through a forest of support bases like a hot knife through butter, but it certainly makes it easier to remove tricky supports from the model itself. Specifically, it excels at slicing through fine areas while preserving delicate features. Continue reading “Making An Ultrasonic Cutter For Post-processing Tiny 3D Prints” →

Cortex 2 Is One Serious 3D Printed Experimental Rocket

December 25, 2018 by Donald Papp 9 Comments

Rocketry is wild, and [Foaly] is sharing build and design details of the Cortex 2 mini rocket which is entirely 3D printed. Don’t let that fool you into thinking it is in any way a gimmick; the Cortex 2 is a serious piece of engineering with some fascinating development.

Cortex 1 was launched as part of C’Space, an event allowing students to launch experimental rockets. Stuffed with sensors and entirely 3D printed, Cortex 1 flew well, but the parachute failed to deploy mainly due to an imperfectly bonded assembly. The hatch was recovered, but the rocket was lost. Lessons were learned, and Cortex 2 was drafted up before the end of the event.

Some of the changes included tweaking the shape and reducing weight, and the refinements also led to reducing the number of fins from four to three. The fins for Cortex 2 are also reinforced with carbon fiber inserts and are bolted on to the main body.

Here’s an interesting details: apparently keeping the original fins would result in a rocket that was “overstable”. We didn’t really realize that was a thing. The results of overstabilizing are similar to a PID loop where gain is too high, and overcorrection results in oscillations instead of a nice stable trajectory.

Cortex 2 uses a different rocket motor from its predecessor, which led to another interesting design issue. The new motor is similar to hobby solid rocket motors where a small explosive charge at the top of the motor blows some time after the fuel is gone. This charge is meant to eject a parachute, but the Cortex 2 is not designed to use this method, and so the gasses must be vented. [Foaly] was understandably not enthusiastic about venting hot gasses through the mostly-PLA rocket body. Instead, a cylindrical cartridge was designed that both encases the motor and redirects any gasses from the explosive charge out the rear of the rocket. That cartridge was SLA printed out of what looks to us like Formlabs’ High Tempurature Resin.

Finally, to address the reasons Cortex 1 crashed, the hatch and parachute were redesigned for better reliability. A servo takes care of activating the system, and a couple of reverse-polarity magnets assist in ensuring the hatch blows clear. There’s even a small servo that takes care of retracting the launch guide.

The rocket is only half built so far, but looks absolutely fantastic and we can’t wait to see more. It’s clear [Foaly] has a lot of experience and knowledge. After all, [Foaly] did convert a Makerbot printer into a CNC circuitboard engraver.