A Vernier Take On A 3D Printer Extruder Indicator

A common way to visualize that a 3D printer’s extruder motor — which feeds the filament into the hot end — is moving is to attach a small indicator to the exposed end of the motor’s shaft. As the shaft turns, so does the attached indicator.

Small movements of the motor are therefore turned into larger movements of something else. So far, so simple. But what about visualizing very small extrusions, such as those tiny ones made during ironing?

[Jack]’s solution is a Vernier indicator for the extruder. Even the smallest movements of the extruder motor’s shaft are made clearly visible by such a device, as shown in the header image above. Vernier scales are more commonly found on measurement tools, and the concept is somewhat loosely borrowed here.

The usual way these lightweight indicators are attached is with a small magnet, and you can read all about them and see examples here.

This new design is basically the same, it simply has a background in a contrasting color added into the mix. [Jack]’s design is intended for the Bambu A1 printer, but the idea can be easily adapted. Give it a look if you find yourself yearning for a bit more visibility in your extruder movements.

Plasma Cutter Gets CNC Treatment At Low Cost

[Daniel] has been metalworking on a budget for a while now. Originally doing things like plasma cutting on old bricks, he used his original plasma cutter to make an appropriate plasma cutting table complete with a water bath which we presume was not only safer but better for his back. Since then he’s stepped up a little more with what might be the lowest-cost CNC plasma cutter that can reliably be put together.

The CNC machine uses a handheld plasma cutting torch as its base, which uses a blowback start mechanism making it usable in an automated CNC setup without interfering with the control electronics. This is a common issue with other types of plasma cutters not originally meant for CNC. The torch head only needs slight modifications to fit in a 3D printed housing designed for the CNC machine which involves little more than slightly changing the angle of the incoming copper tubing and wire and changing the location of the trigger.

With those modifications done, the tool head is ready to be mounted to the CNC machine. [Daniel] has put together a bill of materials for building the entire project for less than $400, which includes the sub-$200 plasma cutter. It’s an impressive bit of sleuthing to get the price down this low, but if you’re still using your plasma cutter by hand on bricks in the yard like [Daniel] used to do make sure to check out that DIY plasma cutting table he built a few years ago too.

Continue reading “Plasma Cutter Gets CNC Treatment At Low Cost”

Corral Some Zippy Blue Flames Into 3D Printed Troughs

[Steve Mould] came across an interesting little phenomenon of blue flames zipping around a circular track. This led to diving down a bit of a rabbit hole about excitable mediums, ultimately leading him to optimize the shapes and come up with some pretty wild variations which he shows off in a video (also embedded below.)

After figuring out that the moving flame depended on combustion of fuel vapor in an environment that didn’t allow for the whole surface to stay lit at once, [Steve] tried to optimize the design of 3d-printed channels and raceways to encourage this effect, and he came up with some pretty novel ones. The 3D models are here if you’d like to try them for yourself (we especially like the “figure eight” and “rays” models.)

The video is an excellent show & tell of everything [Steve] dove into, complete with plenty of demonstrations of harnessing this effect to create some nifty running flames. Check it out in the video below, and if unintuitive physical effects are your thing, don’t miss [Steve]’s peeling apart of the turntable paradox.

Continue reading “Corral Some Zippy Blue Flames Into 3D Printed Troughs”

Alternate Threaded Inserts For 3D Prints

The usual way to put a durable threaded interface into a 3D print is to use a heat-set insert, but what about other options? [Thomas Sanladerer] evaluates a variety of different threaded inserts, none of which are actually made with 3D printing in mind but are useful nevertheless.

There are a number of other easily-available threaded inserts, including the rivnut (or rivet nut), chunky hex socket threaded inserts intended for wood and furniture, heli-coils or helical inserts (which resemble springs), self-tapping threaded inserts (also sold as thread adapters), and T-nuts or prong nuts. They all are a bit different, but he measures each one and gives a thorough rundown on how they perform, as well as offering his thoughts on what works best.

[Thomas] only tests M5 fasteners in this video, so keep that in mind if you get ideas and go shopping for new hardware. Some of the tested inserts aren’t commonly available in smaller sizes. Self-tapping threaded inserts, for example, are available all the way down to M2, but the hex socket threaded inserts don’t seem to come any smaller than M4.

These threaded inserts might be just what your next project calls for, so keep them in mind. Heat-set inserts are of course still a great option, and our own Sonya Vasquez can tell you everything you need to know about installing heat-set inserts into 3D printed parts in a way that leaves them looking super professional.

Continue reading “Alternate Threaded Inserts For 3D Prints”

2024 Home Sweet Home Automation: [HEX]POD – Climate Tracker And Digital Nose

[eBender] was travelling India with friends, when one got sick. Unable to find a thermometer anywhere during COVID, they finally ended up in a hospital. After being evacuated back home, [eBender] hatched an idea to create a portable gadget featuring a few travel essentials: the ability to measure body temperature and heart rate, a power bank and an illumination source. The scope evolved quite a lot, with the concept being to create a learning platform for environmental multi-sensor fusion. The current cut-down development kit hosts just the air quality measurement components, but expansion from this base shouldn’t be too hard.

ML for Hackers: Fiddle with that Tensor Flow

This project’s execution is excellent, with a hexagon-shaped enclosure and PCBs stacked within. As everyone knows, hexagons are the bestagons. The platform currently hosts SCD41 and SGP41 sensors for air quality, a BME688 for gas detection, LTR-308 for ambient light and motion, and many temperature sensors.

On top sits a 1.69-inch IPS LCD, with an OLED display on the side for always-on visualization. The user interface is completed with a joystick and a couple of buttons. An internal blower fan is ducted around the sensor array to pull not-so-fresh air from outside for evaluation. Control is courtesy of an ESP32 module, with the gory details buried deep in the extensive project logs, which show sensors and other parts being swapped in and out.

On the software side, some preliminary work is being done on training TensorFlow to learn the sensor fusion inputs. This is no simple task. Finally, we would have a complete package if [eBender] could source a hexagonal LCD to showcase that hexagon-orientated GUI. However, we doubt such a thing exists, which is a shame.

There are many air quality sensors on the market now, so we see a few hacks based on them, like this simple AQ sensor hub. Let’s not forget the importance of environmental CO2 detection; here’s something to get you started.

Retro Hackintosh Made From Retro Parts

Apple as a company, has staked most of its future around being a “walled garden” where it controls everything from the hardware up through the user experience. In some ways this is good for users; the hardware is generally high quality and vetted by the company creating the software, making for a very uniform experience. This won’t stop some people from trying to get Apple’s operating systems and other software running on unapproved hardware though. These “Hackintosh” computers were much more common in the Intel era but this replica goes even further back to the Macintosh era.

Originally [Kevin] had ordered an authentic Macintosh with the intent of getting it working again, but a broken floppy disk drive and lack of replacement parts turned this project into a different beast. He used the Mac instead as a model for a new 3D-printed case, spending a ton of time sanding, filling, and finishing it to get it to look nearly indistinguishable from the original. The hardware going in this replica is an old Linux-based thin client machine running the Mini vMac operating system, with a modified floppy drive the computer uses to boot. A hidden SD card slot helps interface with modern computers. The display is a modern LCD, though a sheet of acrylic glued to the front panel replicates a bit of the CRT curve.

Click through to read on!

Continue reading “Retro Hackintosh Made From Retro Parts”

A portable digital radio transceiver in a 3d printed case

RNODE: A Portable Unrestricted Digital Radio

RNode is an open source, unrestricted digital radio transceiver based on — but not limited to — the Reticulum cryptographic networking stack. It is another interesting project in what we might call the “Federated application” space in that it is intended to be used with no central controlling body. It can be used in a LAN or WAN context with the Reticulum network when operating in network adaptor mode, but it also has other use cases.

Essentially, RNode is a software project running on a LilyGO LoRa32 board wrapped up in a snazzy-looking 3D-printed case. Just make sure to grab a version of the board with an u.FL connector in place or somewhere to solder one. If it comes with an SMA connector, you will want to remove that. The device can be standalone, perhaps attached to a mobile device via Wi-Fi, but it needs to be hooked up to a laptop for the really interesting applications. When set to TNC mode, it can act as an APRS gateway, which allows you to access packet radio BBSs and all that fun stuff.

Continue reading “RNODE: A Portable Unrestricted Digital Radio”