3d printed

607 Articles

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.

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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.

FatPiBoy: Respin Game Boy With A Pop-Out Controller

November 20, 2017 by 5 Comments

Have you ever found yourself wishing you had a clone of the Game Boy, except it was actually twice as wide, and instead of holding it in your hands you pop a tiny separate controller out of the middle and play it that way? No? Well, neither have we. But that didn’t stop [Christian Reinbacher] from designing and building exactly that, and by the looks of the finished product, we have to say he might be onto something.

To be fair, the charmingly-named FatPiBoy is not really meant to be played like the GameBoy of yesteryear. It’s more like a game console with built in display; you prop the console up on something, and then remove the controller from the system and play that way.

The controller itself is a commercial product, the 8bitdo Zero, but [Christian] based the rest of the system on parts intended for the Adafruit PiGRRL. For the battery, [Christian] used a 4,500 mAh pack that was originally from his Nexus 7 tablet; a tip to keep in mind next time you’re looking for a big and cheap lithium-ion battery.

[Christian] notes that the case design isn’t perfect. There’s currently no external access to the Pi’s USB ports, and the recess for the 8bitdo Zero could be a few millimeters deeper. Still, we think he did an excellent job finishing the case and giving it a professional look; the case and controller look like nearly a perfect match.

This isn’t the first time we’ve seen a Raspberry Pi put on a GameBoy costume, but the FatPiBoy does bring something new to the table with its removable controller. Of course, if you think the controller [Christian] selected for this build is a bit too small, you can always substitute your own…

Gorgeous Engineering Inside Wheels Of A Robotic Trail Buddy

November 19, 2017 by 23 Comments

Robots are great in general, and [taylor] is currently working on something a bit unusual: a 3D printed explorer robot to autonomously follow outdoor trails, named Rover. Rover is still under development, and [taylor] recently completed the drive system and body designs, all shared via OnShape.

Rover has 3D printed 4.3:1 reduction planetary gearboxes embedded into each wheel, with off the shelf bearings and brushless motors. A Raspberry Pi sits in the driver’s seat, and the goal is to use a version of NVIDA’s TrailNet framework for GPS-free navigation of paths. As a result, [taylor] hopes to end up with a robotic “trail buddy” that can be made with off-the-shelf components and 3D printed parts.

Moving the motors and gearboxes into the wheels themselves makes for a very small main body to the robot, and it’s more than a bit strange to see the wheel spinning opposite to the wheel’s hub. Check out the video showcasing the latest development of the wheels, embedded below.

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Visual 3D Print Finishing Guide

November 15, 2017 by 52 Comments

With 3D printers now dropping to record low prices, more and more people are getting on the additive manufacturing bandwagon. As a long time believer in consumer-level desktop 3D printing, this is a very exciting time for me; the creativity coming out of places like Thingiverse or the 3D printing communities on Reddit is absolutely incredible. But the realist in me knows that despite what slick promotional material from the manufacturers may lead you to believe, these aren’t Star Trek-level replicators. What comes out of these machines is often riddled with imperfections (from small to soul crushing), and can require considerable cleanup work before they start to look like finished pieces.

If all you hope to get out of your 3D printer are some decent toy boats and some low-poly Pokemon, then have no fear. Even the most finicky of cheap printers can pump those out all day. But if you’re looking to build display pieces, cosplay props, or even prototypes that are worth showing to investors, you’ve got some work cut out for you.

With time, patience, and a few commercial products, you can accomplish the ultimate goal: turning a 3D printed object into something that doesn’t look like it was 3D printed. For the purposes of this demonstration I’ll be creating a replica of the mobile emitter used by the “Emergency Medical Hologram” in Star Trek: Voyager. I can neither confirm nor deny I selected this example due to the fact that I’m currently re-watching Voyager on Netflix. Let’s make it look good.

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