3d printed

568 Articles

Ergonomic Keyboard Designed From The Ground Up

December 28, 2017 by 15 Comments

In 2011, [Fabio] had been working behind a keyboard for about a decade when he started noticing wrist pain. This is a common long-term injury for people at desk jobs, but rather than buy an ergonomic keyboard he decided that none of the commercial offerings had all of the features he needed. Instead, he set out on a five-year journey to build the perfect ergonomic keyboard.

Part of the problem with other solutions was that no keyboards could be left in Dvorak (a keyboard layout [Fabio] finds improves his typing speed) after rebooting the computer, and Arduino-based solutions would not make themselves available to the computer’s BIOS. Luckily he found the LUFA keyboard library, and then was able to salvage a PCB from another keyboard. From there, he programmed everything on a Teensy microcontroller, added an OLED screen, and soldered it all together (including a set of Cherry MX switches).

Of course, the build wasn’t truly complete until recently, when a custom two-part case was 3D printed. The build quality and attention to detail in this project is impressive, and if you want to roll out your own [Fabio] has made all of the CAD files and software available. Should you wish to incorporate some of his designs into other types of specialized keyboards, there are some ideas floating around that will surely improve your typing or workflow.

Wishing The Family A Sinusoidal Christmas

December 24, 2017 by 16 Comments

When it’s time to put together the annual Christmas card, most families take a few pictures of the kids, slap on a generic greeting, and call it a day. It used to be fairly common for the whole family to get dressed up and pose for a special Christmas picture, but who has the time anymore? It’s not like we have hours and hours to slave over a unique and memorable gift we can mail out to a dozen (or more) people.

Unless you’re [Chris Wolsey], anyway. Rather than take the easy way out and simply mailing some pictures of his daughter out to friends and family, he recorded her giving a Christmas greeting and turned the waveform of her voice into a framed physical memento. Way to wreck the curve for the rest of us, [Chris].

Evolution of the printed waveform.

As it turns out, getting sound into CAD software isn’t exactly straightforward. To start, he made a recording of his daughter saying the words “Happy Christmas From the Wolsey Family” with Audacity, and then took a screenshot of the resulting waveform. This screenshot was then brought into Adobe Illustrator and exported to SVG, which Fusion 360 (and most other CAD packages) is able to import.

Now that the wave was in Fusion 360 he could scale it to a reasonable size, and use the revolve function to bring it into three dimensions. Cutting that object in half down the length then gave [Chris] a shape which should, theoretically, be printable on his FDM printers. But unfortunately, it wasn’t so easy. His personal Anet A8 had a tough time printing it, and the Prusa i3 MK2 at work didn’t fare much better. In the end, he had to make the leap to SLA, getting the shape printed on a Form 2 via 3D Hubs.

With the finalized shape in hand, [Chris] just need to put them into production. Printing them all via 3D Hubs wasn’t really an option, so he decided to make a mold and cast them in resin. He printed up a mold box, and after fiddling around with the mix a bit, was able to settle on a resin which allowed him to de-mold the shapes just 30 minutes after pouring.

Finally, he made frames for each cast waveform, and printed up a little label explaining just what the recipient was looking at; even going as far as showing which word corresponded to which section of the shape.

This is a fantastically executed and documented project, and while it’s too late to whip up your own version this year, we have no doubt they’ll be a few people “borrowing” this idea next time the holidays roll around.

It’s never too early to start planning for next Christmas. We’ve covered unique takes on the traditional holiday card before, as well as a sleighful of holiday decorating projects.

A Gloriously Impractical Electromechanical Display

December 19, 2017 by 28 Comments

For this year’s office holiday party, [Gavan Fantom] wanted to do something really special. Coworkers were messing with LEDs to come up with displays and decorations, but they lack that old-school feel of mechanical displays. He wanted to create something that had retro look of moving elements, but didn’t want to just recreate the traditional flip mechanism we’ve all seen over and over.

The mechanism to drive a single “pixel”.

What [Gavan] came up with is breathtakingly impractical 8×8 display that sounds as cool as it looks. Each “pixel” in the display is a 3D printed screw mechanism rotated by a hobby servo. As the pixel is rotated in its case, it becomes progressively more visible to the observer. The opacity of the pixel can even be adjusted by varying the degree of rotation, allowing for rudimentary display of grayscale images.

Each element in the display is made up of seven 3D printed parts and two nails, which the mechanism slides on to move forward and backward. An 8×8 display needs 64 elements, which means the entire display needs 64 servos, 128 nails, and a whopping 448 3D-printed parts. Even with two printers attacking the production in parallel, the printing alone took over two weeks to complete.

The display is powered by a Raspberry Pi and three “Mini Maestro” controllers which can each handle 24 servos. [Gavan] found some sample code in Python to pass commands to the Maestro servo controllers, which he used as a template when writing his own software. The Python script opens image files, converts them to grayscale, and then maps the value of each pixel to rotation of the corresponding servo. He says the software is a little rough and that there’s still some calibration to be done, but we think the results are phenomenal so far.

Mechanical displays are a favorite of hackers, due in no small part to the awesome noises they make while in operation. While we’ve seen some very creative approaches to this type of display before, what [Gavan] has created here is certainly in a league of its own.

Continue reading “A Gloriously Impractical Electromechanical Display” →

Small Jet Engine Model From Students Who Think Big

December 18, 2017 by 21 Comments

We love to highlight great engineering student projects at Hackaday. We also love environment-sensing microcontrollers, 3D printing, and jet engines. The X-Plorer 1 by JetX Engineering checks all the boxes.

This engineering student exercise took its members through the development process of a jet engine. Starting from a set of requirements to meet, they designed their engine and analyzed it in software before embarking on physical model assembly. An engine monitoring system was developed in parallel and integrated into the model. These embedded sensors gave performance feedback, and armed with data the team iterated though ideas to improve their design. It’s a shame the X-Plorer 1 model had to stop short of actual combustion. The realities of 3D printed plastic meant airflow for the model came from external compressed air and not from burning fuel.

Also worth noting are the people behind this project. JetX Engineering describe themselves as an University of Glasgow student club for jet engine enthusiasts, but they act less like a casual gathering of friends and more like an aerospace engineering firm. The ability of this group to organize and execute on this project, including finding sponsors to fund it, are skills difficult to teach in a classroom and even more difficult to test with an exam.

After X-Plorer 1, the group has launched two new project teams X-Plorer 2 and Kronos. They are also working to expand to other universities with the ambition of launching competitions between student teams. That would be exciting and we wish them success.

Continue reading “Small Jet Engine Model From Students Who Think Big” →

If 3D Printer, Then Custom Aluminum Extrusion Brackets

December 16, 2017 by 63 Comments

Aluminum extrusions are a boon for mechanical assemblies, but they require a stock of brackets and other hardware to be kept on hand. [mightynozzle] has decided to make things a little easier for prototyping and low-stress assemblies by creating a collection of 3D printable brackets for aluminum extrusions. 3D printing your own bracket hardware means faster prototyping, and if the assemblies don’t need the extra strength and rigidity of metal brackets you can just stick with the 3D printed versions.

The files are on Thingiverse, and include STL files of common brackets as well as an OpenSCAD script for customizing. Not familiar with OpenSCAD? No problem, we have a quick primer with examples.

This project showcases two things well. The first is that while brackets are not particularly expensive or hard to obtain, it can still be worth 3D printing them to reduce the overall amount of hardware one needs to keep on hand to make prototyping faster. The other is that 3D printing can shine when it comes to the creation of things like brackets: a few dimes’ worth of plastic can be turned into precise yet geometrically simple objects that would be a pain to make by other means. It certainly beats sitting on one’s hands waiting for parts to be delivered.

ESP8266 Home Monitor Is Stylishly Simplistic

November 20, 2017 by 18 Comments

It’s often said that “Less is More”, and we think that the chic ESP8266 environmental monitor posted by Thingiverse user [bkpsu] definitely fits the bill. Dubbed “Kube”, the device is a 3D printed white cube with an OLED display in the center, which [bkpsu] says was designed specifically for the approval of his wife. Weirdly, she didn’t like the look of bare PCBs on the wall.

Multiple Kubes allow for whole-house monitoring.

Inside, things are a little more complex. The Kube uses the NodeMCU development board, and a custom breakout that [bkpsu] designed to interface with the display and sensors. For temperature and humidity monitoring, the Kube is using the ever-popular DHT22, and [bkpsu] mentions that he has future plans for things like motion sensors and direct control of RGB LED strips. All the data collected by the Kube is piped into openHAB via MQTT.

On the very detailed Thingiverse page, [bkpsu] gives background information on his design goals for the project, tips for printing out a high-quality case, a parts list with Amazon links, and pinout information for getting it all wired up. The PCB is even available on OSH Park for those who want a Kube of their own.

Even with all the stick home monitoring and automation products on the market today, many hackers simply can’t bring themselves to buying a turn-key commercial product. But we think with the results hackers have been getting rolling their own solutions, they just might be on to something.