3D Printer Bed Probing Using A Tact Switch And Coin Cell

October 26, 2021 by Al Williams 39 Comments

Inspired by his CNC’s leveling system, [Chuck] built a small PCB to help level his 3D printer and he shares the details in the video you can see below. The idea is simple, the nozzle pushes down on the PCB which has a tact switch underneath. When the switch closes, an LED lights.

In practice, you measure the height of the board and use that for your Z offset, and you are done. Our only concern would be how repeatable the switch is. Granted, most people use a piece of paper and that’s probably not totally repeatable or accurate either. Proper feeler gauges are the “right” way to do it, but we know only a few people who do that.

If you ever look into the repeatability of various Z probes like the proximity sensors or the little pins that drop out of a 3D Touch probe, they aren’t that repeatable. Some people use microswitches, too, which is pretty similar to this approach and is apparently good enough.

The board is available, but it is simple enough that you could create it — or an equivalent — with just about any method you use for your PCBs. [Chuck’s] prototype board was milled. We are always surprised more people don’t use the nozzle itself to sense the bed. Some people go to a lot more trouble than just electrical contact even for CNC.

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3D Printer Cuts Metal

October 22, 2021 by Bryan Cockfield 19 Comments

Every now and then we’ll see a 3D printer that can print an entire house out of concrete or print an entire rocket out of metal. But usually, for our budget-friendly hobbyist needs, most of our 3D printers will be printing small plastic parts. If you have patience and a little bit of salt water, though, take a look at this 3D printer which has been modified to cut parts out of any type of metal, built by [Morlock] who has turned a printer into a 5-axis CNC machine.

Of course, this modification isn’t 3D printing metal. It convers a 3D printer’s CNC capabilities to turn it into a machining tool that uses electrochemical machining (ECM). This process removes metal from a work piece by passing an electrode over the metal in the presence of salt water to corrode the metal away rapidly. This is a remarkably precise way to cut metal without needing expensive or heavy machining tools which uses parts that can easily be 3D printed or are otherwise easy to obtain. By using the 3D printer axes and modifying the print bed to be saltwater-resistant, metal parts of up to 3 mm can be cut, regardless of the type of metal used. [Morlock] also added two extra axes to the cutting tool, allowing it to make cuts in the metal at odd angles.

Using a 3D printer to perform CNC machining like this is an excellent way to get the performance of a machine tool without needing to incur the expense of one. Of course, it takes some significant modification of a 3D printer but it doesn’t need the strength and ridigity that you would otherwise need for a standard CNC machine in order to get parts out of it with acceptable tolerances. If you’re interested in bootstraping one like that using more traditional means, though, we recently featured a CNC machine that can be made from common materials and put together for a minimum of cost.

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Testing 3D Printed Cutting Blades Is Scary Work

October 22, 2021 by Lewin Day 15 Comments

[Ivan Miranda] comes from a land where the shops close on Sundays. Thus, when he found himself in need of a cutting blade, he realised he would have to build his own, or simply wait. He elected to do the former, and we get to enjoy the journey. (Video, embedded below.)

His first attempt was to cut a wooden plank with a 3D-printed cutting blade fitted to a mitre saw. After setting up the mitre saw to cut while he was at a safe distance, [Ivan] elected to test the blade. Alas, it simply melted, and the wood was barely scratched, so [Ivan] went back to the drawing board.

His second attempt was to CNC mill an aluminium blade, which was a full 6 mm thick. The saw needed some modifications to the saw to fit properly, but it was able to cut wood without major drama!

Returning to the 3D-printed concept, [Ivan] suspected reducing the surface speed of the cutting disc could reduce friction-induced heating. This would allow the 3D-printed blade to cut wood without melting, in theory. To achieve this, he built his own basic drop saw using a steel frame and a brushless motor. With a little water spray, and careful control of speed and pressure, the blade was able to slowly chew through a plank of wood. Afterwards, the teeth were almost completely worn down.

The fact is, 3D-printed blades are usually going to be too soft to do any real useful work. However, it’s fun to watch, and that’s good enough for us. If you want something more useful though, consider building your own knives.

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Inconsistent layer heights in a 3D print

An Easy Fix For Inconsistent Layers In Cheap 3D Printers

October 17, 2021 by Dan Maloney 26 Comments

If there’s one thing you can say about [Stefan] from CNC Kitchen, it’s that he’s methodical when he’s working on an improvement to his 3D printing processes, or when he’s chasing down a problem with a printer. Case in point: this root-cause analysis of extrusion inconsistencies with an entry-level 3D printer.

The printer in question is a Cetus MK3, a printer that found its way onto many benches due to its ridiculously low price and high-quality linear bearings. Unfortunately, there’s still a lot to be desired about the printer, and its tendency for inconsistent layers was chief among [Stefan]’s gripes. Such “blubbiness” can be pinned on any number of problems, but rather than guess, [Stefan] went through a systematic process of elimination to find the root cause. We won’t spoil the ending, but suffice it to say that the problem was subtle, and could probably be the cause of similar problems with other printers. The fix was also easy, and completely mechanical — just a couple of parts to replace. The video below shows the whole diagnosis process, as well as the before and after comparisons. [Stefan] also teases an upcoming treatment on how he converted the Cetus from the stock proprietary control board, which we’re interested in seeing.

If you haven’t checked out any of [Stefan]’s other 3D printing videos, you really should take a look. Whether it’s vibration damping with a concrete paver, salt annealing prints for strength, or using finite element analysis to optimize infills, he’s always got an interesting take on 3D printing.

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Erasable Pen Ink Adds Colors To 3D Prints

September 28, 2021 by Bryan Cockfield 8 Comments

Changing colors during a 3D print is notoriously difficult. Either you need multiple heads ready to go during the print which increases operating and maintenance costs for your printer, or you need to stop the print to switch the filament and then hope that everything matches up when the print is resumed. There are some workarounds to this problem, but not many of them are as smooth an effortless as this one which uses erasable pen ink to add colors to the filament on the fly.

Erasable pen ink is a thermochromic material that doesn’t get removed from paper when erased like graphite from a pencil. Instead the heat from the friction of erasing causes it to become transparent. By using this property for a 3D print, the colors in the print can be manipulated simply by changing the temperature of the hot end. Of course the team at [Autodrop3d] had quite a learning curve when experimenting with this method, as they had to run the extruder at a much lower temperature than normal to have control over the ink’s color, had to run the print much slower than normal, and were using a very sticky low-temperature plastic for the print.

With all of these modifications to the print setup, there are bound to be some limitations in material and speed, but the results of the project speak for themselves. This allows for stock 3D printers to use this method with no hardware modifications, and the color changes can be done entirely in software. While everyone catches up with this new technology, there are some other benefits to a 3D printer with multiple print heads, though, and some clever ways of doing the switching without too much interruption.

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3D Printering: Is Hassle-Free Bed Leveling Finally Here?

August 30, 2021 by Donald Papp 71 Comments

3D printers have come a long way over the past several years, but the process of bed leveling remains a pain point. Let’s take a look at the different ways the problem has been tackled, and whether recent developments have succeeded in automating away the hassle.

Anycubic Vyper 3D printer, front view — Anycubic Vyper, with an auto-leveling feature we decided to take a closer look at.

Bed leveling and first layer calibration tends to trip up novices because getting it right requires experience and judgment calls, and getting it wrong means failed prints. These are things 3D printer operators learn to handle with time and experience, but they are still largely manual processes that are often discussed in ways that sound more like an art than anything else. Little wonder that there have been plenty of attempts to simplify the whole process.

Some consumer 3D printers are taking a new approach to bed leveling and first layer calibration, and one of those printers is the Anycubic Vyper, which offers a one-touch solution for novices and experienced users alike. We accepted Anycubic’s offer of a sample printer specifically to examine this new leveling approach, so let’s take a look at the latest in trying to automate away the sometimes stubborn task of 3D printer bed leveling.

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A Simpsons TV For A Golden Age

August 26, 2021 by Bryan Cockfield 17 Comments

While the pace of technology continues to advance at breakneck speed, certain things in the past are left behind largely subject to the whims of nostalgia. Televisions, for example, are lighter, cheaper, and bigger than they were in the early 90s, but they did have a certain design aesthetic that doesn’t exist anymore. Meanwhile, Simpsons episodes have been (arguably) on the decline since the golden age of the 90s, so [buba447] decided to combine these two facets of a nostalgic past into a custom TV that only plays these older Simpsons episodes.

Update: Now there’s a build guide.

The TV is 3D printed but takes design cues from CRT-based technology from decades past. It even has working knobs emblematic of that era as well. Inside the “television” is a Raspberry Pi which is hooked up to a small screen. The Pi powers up and automatically starts playing Simpsons episodes once it boots. There is a power button at the top of the TV which mutes the sound and also turns off the display. As an added touch, the display outputs in 640×480 resolution, which is also somewhat historically accurate, even if the TV itself is much smaller than its ancient relatives.

Of course, the TV only plays episodes from The Simpson’s first eleven seasons, which includes all of the episodes of The Simpson’s golden era (and a few extra) and omits those episodes from the modern era, which will please certain Simpsons fans as well. This actually isn’t the first time we’ve seen a 24 hour Simpsons device. This Pi-based build serves up Simpsons episodes nonstop as well, but sends them out over the airwaves instead.

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