Recreating The Radio From Portal

January 17, 2018 by Tom Nardi 13 Comments

If you’ve played Valve’s masterpiece Portal, there’s probably plenty of details that stick in your mind even a decade after its release. The song at the end, GLaDOS, “The cake is a lie”, and so on. Part of the reason people are still talking about Portal after all these years is because of the imaginative world building that went into it. One of these little nuggets of creativity has stuck with [Alexander Isakov] long enough that it became his personal mission to bring it into the real world. No, it wasn’t the iconic “portal gun” or even one of the oft-quoted robotic turrets. It’s that little clock that plays a jingle when you first start the game.

Alright, so perhaps it isn’t the part of the game that we would be obsessed with turning into a real-life object. But for whatever reason, [Alexander] simply had to have that radio. Of course, being the 21st century and all his version isn’t actually a radio, it’s a Bluetooth speaker. Though he did go through the trouble of adding a fake display showing the same frequency as the one in-game was tuned to.

The model he created of the Portal radio in Fusion 360 is very well done, and available on MyMiniFactory for anyone who might wish to create their own Aperture Science-themed home decor. Though fair warning, due to its size it does consume around 1 kg of plastic for all of the printed parts.

For the internal Bluetooth speaker, [Alexander] used a model which he got for free after eating three packages of potato chips. That sounds about the best possible way to source your components, and if anyone knows other ways we can eat snack food and have electronics sent to our door, please let us know. Even if you don’t have the same eat-for-gear promotion running in your neck of the woods, it looks like adapting the model to a different speaker shouldn’t be too difficult. There’s certainly enough space inside, at least.

Over the years we’ve seen some very impressive Portal builds, going all the way back to the infamous levitating portal gun [Caleb Kraft] built in 2012. Yes, we’ve even seen somebody do the radio before. At this point it’s probably safe to say that Valve can add “Create cultural touchstone” to their one-sheet.

Continue reading “Recreating The Radio From Portal” →

3D Printing A Better Quadcopter Frame

January 15, 2018 by Tom Nardi 22 Comments

Before you smash the “Post Comment” button with the fury of Zeus himself, we’re going to go ahead and say it: if you want to build a decent quadcopter, buy a commercial frame. They are usually one of the cheaper parts of the build, they’re very light for how strong they are, and replacement parts are easily available. While you could argue the cost of PLA/ABS filament is low enough now that printing it would be cheaper than buying, you aren’t going to be able to make a better quadcopter frame on a 3D printer than what’s available on the commercial market.

The frame features a surprisingly low part count.

Having said that, [Paweł Spychalski] has recently shown off his 3D printed FPV racing quadcopter frame with some surprising results. The frame ended up being surprisingly stiff, and while the weight is a bit high, it’s actually lighter than he expected. If you’re looking to build a quad with the absolute minimum of expense his design might be something to look into.

Of course, [Paweł] is hardly the first person to think about printing a quad frame. But he did give his design some extra consideration to try and overcome some of the shortcomings he noticed in existing 3D printed designs. For one, rather than have four separate arms that mount to a central chassis, his design has arms that go all the way across with a thick support that goes between the motors. The central chassis is also reassuringly thick, adding to the overall stiffness of the frame.

The key here is that [Paweł] printed all the parts with 2 mm thick walls. While that naturally equates to longer print times and greater overall weight, it’s probably more than worth it to make sure the frame doesn’t snap in half the first time it touches the ground.

Beyond the printed parts, all you need to assemble this frame are about a dozen M3 nuts and bolts. Overall, between the hardware and the plastic you’re looking at a total cost of under $5 USD. In the video below [Paweł] puts the frame through its paces doing some acrobatic maneuvers, and it looks like 5 bucks well spent to us.

If you want to go all-in on 3D printed quadcopter parts, you can pair this frame with some printed propellers. Perhaps even a printed camera gimbal while you’re at it. Continue reading “3D Printing A Better Quadcopter Frame” →

Aluminum No Match For 3D Printed Press Brake Dies

January 14, 2018 by Tom Nardi 44 Comments

If you’re looking for a get-rich-quick scheme, you can scratch “Doing small-scale manufacturing of ultralight aircraft” off your list right now. Turns out there’s no money in it. At least, not enough money that you can outsource production of all the parts. Not even enough to setup a huge shop full of customized machining tools when you realize you have to make the stuff yourself. No, this sounds like one of those “labors of love” we always hear so much about.

So how does one do in-house manufacturing of aircraft with a bare minimum of tools? Well, since you’re reading this on Hackaday you can probably guess that you’ve got to come up with something a bit unorthodox. When [Brian Carpenter] of Rainbow Aviation needed a very specific die to bend a component for their aircraft, he decided to try designing and 3D printing one himself.

He reasoned that since he had made quick and dirty dies out of wood in the past, that a 3D printed one should work for at least a few bends before falling apart. He even planned to use JB Weld to fill in the parts of the printed die which he assumed would start cracking and breaking off after he put it through a few cycles. But even after bending hundreds of parts, wear on the dies appears to be nearly non-existent. As an added bonus, the printed plastic dies don’t mar the aluminum pieces they are bending like the steel dies do.

So what’s the secret to printing a die that can bend hundreds of pieces of aluminum on a 20 ton brake without wearing down? As it turns out…not a whole lot. [Brian] attributes the success of this experiment to designing the die with sufficiently accurate tolerances and having so high of an infill that it may as well be solid plastic.

In fact, the 3D printed die worked out so well that they’ve now expanded the idea to a cheap Harbor Freight brake. Before this tool was going more or less unused as it didn’t have features they needed for the production of their parts, namely a radius die or backstop. But by 3D printing these components [Brian] was able to put the tool back to work.

We’ve previously covered the art and science of bending sheet metal, as well as a homebuilt brake that let’s you do it on a budget even Rainbow Aviation would scoff at. So what are you waiting for? Go build an airplane.

Thanks to [Oahupilot] for the tip.

Continue reading “Aluminum No Match For 3D Printed Press Brake Dies” →

Not So Simple LED Upgrade For Microscope

January 14, 2018 by Donald Papp 18 Comments

[Amen] obtained a microscope whose light source was an incandescent bulb, but the light from it seemed awfully dim even at its brightest setting. Rather than hunt down a replacement, he decided to replace the bulb with a 1W LED mounted on a metal cylinder. The retrofit was successful, but there were numerous constraints on his work that complicated things. The original bulb and the LED replacement differed not just in shape and size, but also in electrical requirements. The bulb was also part of an assembly that used a two-pronged plug off to the side for power. In the end, [Amen] used 3D printing, a bit of metal work, and a bridge rectifier on some stripboard to successfully replace his microscope’s incandescent bulb assembly with an LED. He even used a lathe to make connector pins that mated properly with the microscope’s proprietary power connector, so that the LED unit could be a drop-in module.

Working on existing equipment always puts constraints on one’s work, usually due to space limitations, but sometimes also proprietary signals. For example, a common issue when refitting a projector with an LED is to discover that the projector expects a stock bulb, and refuses to boot up without one. Happily, the microscope didn’t care much about the bulb itself, and with the LED positioned in roughly the same position as the original bulb’s filament [Amen] obtained smooth and even lighting across the field of view with no changes made to the microscope itself.

Vintage Logan Lathe Gets 3D Printed Gears

January 13, 2018 by Tom Nardi 34 Comments

In December 2016, [Bruno M.] was lucky enough to score a 70+ year old Logan 825 lathe for free from Craigslist. But as you might expect for a piece of machinery older than 95% of the people reading this page, it wasn’t in the best of condition. He’s made plenty of progress so far, and recently started tackling some broken gears in the machine’s transmission. There’s only one problem: the broken gears have a retail price of about $80 USD each. Ouch.

On his blog, [Bruno] documents his attempts at replacing these expensive gears with 3D printed versions, which so far looks very promising. He notes that usually 3D printed gears wouldn’t survive in this sort of application, but the gears in question are actually in a relatively low-stress portion of the transmission. He does mention that he’s still considering repairing the broken gears by filling the gaps left by the missing teeth and filing new ones in, but the 3D printed gears should at least buy him some time.

As it turns out, there’s a plugin available for Fusion 360 that helpfully does all the work of creating gears for you. You just need to enter in basic details like the number of teeth, diametral pitch, pressure angle, thickness, etc. He loaded up the generated STL in Cura, and ran off a test gear on his delta printer.

Of course, it didn’t work. Desktop 3D printing is still a finicky endeavour, and [Bruno] found with a pair of digital calipers that the printed gear was about 10% larger than the desired dimensions. It would have been interesting to find out if the issue was something in the printer (such as over-extrusion) or in the Fusion 360 plugin. In any event, a quick tweak to the slicer scale factor was all it took to get a workable gear printed on the third try.

This isn’t the first time we’ve seen 3D printed gears stand in for more suitable replacement parts, nor the first time we’ve seen them in situations that would appear beyond their capability. As 3D printer hardware and software improves, it seems fewer and fewer of the old caveats apply.

Continue reading “Vintage Logan Lathe Gets 3D Printed Gears” →

Rolling Robot With Two Motors, But None Are On The Wheels

January 12, 2018 by Donald Papp 4 Comments

This unusual 3D printed Rolling Robot by [ebaera] uses two tiny hobby servos for locomotion in an unexpected way. The motors drive the front wheel only indirectly, by moving two articulated arms in a reach-and-retract motion similar to a breaststroke. The arms are joined together at the front, where a ratcheting wheel rests underneath. When the arms extend, the wheel rolls forward freely. When the arms retract, the wheel’s ratchet locks and the rest of the body is pulled forward. It looks as though extending one arm more than the other provides for rudimentary steering.

The parts are all 3D printed but some of them look as though they might be a challenge to print well due to the number of small pieces and overhangs. A short video (embedded below) demonstrates how it all works together; the action starts about 25 seconds in.

Continue reading “Rolling Robot With Two Motors, But None Are On The Wheels” →

Printed PC Speakers Are Way Cooler Than Yours

January 12, 2018 by Tom Nardi 21 Comments

On the off chance you’re reading these words on an actual desktop computer (rather than a phone, tablet, smart mirror, game console…), stop and look at the speakers you have on either side of your monitor. Are you back now? OK, now look at the PC speakers and amplifier [Kris Slyka] recently built and realize you’ve been bested. Don’t feel bad, she’s got us beat as well.

The speaker and amplifier enclosures were painstakingly printed and assembled over the course of three months, and each piece was designed to be small enough to fit onto the roughly 4 in x 4 in bed of her PrintrBot Play. While limited print volume made the design considerably trickier, it did force [Kris] to adopt a modular design approach with arguably made assembly (and potential future repairs or improvements) easier.

The amplifier is made up of rectangular “cells” which are connected to each other via 3 mm threaded rods. For now the amplifier only has 4 cells, but this could easily be expanded in the future without having to design and print a whole new case. Internally the amplifier is using two TDA8932 digital amplifier modules, and some VU meters scored off of eBay.

Each speaker enclosure is made up of 10 individual printed parts that are then glued and screwed together to make the final shape, which [Kris] mentions was inspired by an audio installation at the Los Angeles County Museum of Art. They house 4″ Visaton FR 10 HM drivers, and are stuffed with insulation.

It’s a bit difficult to nail down the style that [Kris] has gone for here. You see the chunky controls and analog VU meters and want to call it retro, but it’s also a brass cog and sprocket away from being Steampunk. On the other hand, the shape of the speakers combined with the bamboo-filled PLA used to print them almost gives it an organic look: as if there’s a tree somewhere that grows these things. That’s actually a kind of terrifying thought, but you get the idea.

If your computer speakers were assembled by mere mortals, never fear. We’ve covered a number of interesting hacks and mods for more run-of-the-mill desktop audio setups which should hold you over until it’s time to harvest the speaker trees.

[via /r/3Dprinting]