Dynamic Build Platforms For 3D Printers Remove Supports And Save Material

April 10, 2021 by Bob Baddeley 31 Comments

We’re all too familiar with the 3D printing post-processing step of removing supports, and lamenting the waste of plastic on yet another dwindling reel of filament. When the material is expensive NinjaFlex or exotic bio-printers, printing support is downright painful. A group at USC has come up with a novel way of significantly reducing the amount of material that’s 3D printed by raising portions of the bed over time, and it makes us wonder why a simpler version isn’t done regularly.

In the USC version, the bed has a bunch of square flat metal pieces, with a metal tube underneath each. The length of the tube determines the eventual height of that square. Before the print is made, the bed is prepared by inserting the appropriate length tubes in the correct squares. Then, during the print, a single motor pushes a platform up, and based on the height of the pin, that portion of the bed raises appropriately, then stops at the right height.

This is a significant savings over having a matrix of linear motors or servos to control each square, at the cost of having to prepare the pins for each print.

But it has us wondering; since CURA and other slicing software have the ability to pause at height, what if the slicing software could allow for the placement of spacer blocks of a known size? The user would have a variety of reusable spacer blocks, and position them in the software, and the slicer would build the support material starting on top of the block. It could print a rectangle on the base layer to aid in proper placement of the blocks during printing, and pause at the correct heights to let the user insert the blocks. At the end of the print a lot less support material has been used.

For situations where you want to leave your print to run unattended, or if the cost of the material is low enough that it doesn’t justify the effort, then maybe this isn’t worth it. Another problem might be heating that platform, though since only support material will be printed on it, some curling won’t matter much. What do you think?

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Get A Better Look At E3D’s Tool-changing 3D Printer Kit

March 20, 2021 by Donald Papp 4 Comments

Want a closer, in-depth look at E3D’s motion system and tool-changing platform? [Kubi Sertoglu] shared his impressions after building and testing the system, which comes in the form of a parts bundle direct from E3D costing just under $3000 USD. The project took [Kubi] about 15 hours and is essentially built from the ground up. The system is definitely aimed at engineers and advanced prosumers, but [Kubi] found it to be of remarkable quality, and is highly pleased with the end results.

E3D Motion system and toolchanger, with four extruders

We first saw E3D’s design announced back in 2018, when they showed their working ideas for a system that combined motion control and a toolchanger design. The system [Kubi] built uses four 3D printing extruders for multi-material prints, but in theory the toolheads could just as easily be things like grippers, lasers, or engravers instead of 3D printing extruders.

One challenge with tool changing is ensuring tools mount and locate back into the same place, time after time. After all, a few fractions of a millimeter difference in the position of a print head would spell disaster for the quality of most prints. Kinematic couplings are the answer to being sure something goes back where it should, but knowing the solution is only half the battle. Implementation still requires plenty of clever design and hard engineering work, which is what E3D has delivered.

Want a closer look at the nitty-gritty? Check out E3D’s GitHub repository for all the details on their toolchanger and motion system.

Motorcycle Needs Custom Latching Switches For Turn Signals

March 13, 2021 by Bryan Cockfield 42 Comments

While modern cars have been getting all kinds of fancy features like touch screens, Bluetooth, crumple zones, and steering wheel controls, plenty of motorcycles have remained firmly in the past. Some might have extra options like a fuel gauge or even ABS if you’re willing to spend extra, but a good percentage of them have the bare minimum equipment required by law. That equipment is outdated and ripe for some improvements too, like this ergonomic custom turn signal switch built with custom latching switches.

Since motorcycle turn signals don’t self-cancel like car signals the rider has to cancel it themselves, usually by pushing an inconveniently tiny button. This assembly consists of four separate switches, two of which control the left and right turn signals. Since both can’t be on at the same time, they include circuitry that can detect their position and a small motor that can physically de-latch them if the other one is pressed. The entire assembly is 3D printed, including the latching mechanism, and they are tied together with a small microcontroller for the controls.

The truly impressive part of this build is the miniaturization, since all four buttons have to be reached with the thumb without removing the hand from the handlebar. The tiny circuitry and mechanical cam for latching are impressive and worth watching the video for. And, if you need more ergonomic improvements for your motorcycle there are also some options for cruise control as well, another feature often lacking in motorcycles.

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Print Chess Pieces, Then Defeat The Chess-Playing Printer

March 6, 2021 by Brian McEvoy 4 Comments

Chess is undoubtedly a game of the mind. Sadly, some of the nuances are lost when you play on a computer screen. When a game is tactile, it carries a different gravity. Look at a poker player shuffling chips, and you’ll see that when a physical object is on the line, you play for keeps. [Matou], who is no stranger to 3D printing, wanted that tactility, but he didn’t stop at 3D printed pieces. He made parts to transform his Creality Ender 3 Pro into a chess-playing robot.

To convert his printer, [Matou] designed a kit that fits over the print head to turn a hotend into a cool gripper. The extruder motor now pulls a string to close the claw, which is a darn clever way to repurpose the mechanism. A webcam watches the action, while machine vision determines what the player is doing, then queries a chess AI, and sends the next move to OctoPrint on a connected RasPi. If two people had similar setups, it should be no trouble to play tactile chess from opposite ends of the globe.

Physical chess pieces and computers have mixed for a while and probably claimed equal time for design and gameplay. There are a couple of approaches to automating movement from lifting like [Matou], or you can keep them in contact with the board and move them from below.

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Electroplating 3D Printed Parts For Great Strength

March 1, 2021 by Bryan Cockfield 33 Comments

Resin 3D printers have a significant advantage over filament printers in that they are able to print smaller parts with more fine detail. The main downside is that the resin parts aren’t typically as strong or durable as their filament counterparts. For this reason they’re often used more for small models than for working parts, but [Breaking Taps] wanted to try and improve on the strength of these builds buy adding metal to them through electroplating.

Both copper and nickel coatings are used for these test setups, each with different effects to the resin prints. The nickel adds a dramatic amount of stiffness and the copper seems to increase the amount of strain that the resin part can tolerate — although [Breaking Taps] discusses some issues with this result.

While the results of electroplating resin are encouraging, he notes that it is a cumbersome process. It’s a multi-step ordeal to paint the resin with a special paint which helps the metal to adhere, and then electroplate it. It’s also difficult to ensure an even coating of metal on more complex prints than on the simpler samples he uses in this video.

After everything is said and done, however, if a working part needs to be smaller than a filament printer can produce or needs finer detail, this is a pretty handy way of adding more strength or stiffness to these parts. There’s still some investigating to be done, though, as electroplated filament prints are difficult to test with his setup, but it does show promise. Perhaps one day we’ll be able to print with this amount of precision using metal directly rather than coating plastic with it.

Thanks to [smellsofbikes] for the tip!

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Simple 3D Printed Seven-Segment Displays

February 2, 2021 by Lewin Day 7 Comments

7-segment LED displays were revolutionary, finally providing a clear, readable and low-power numerical display solution. We’ve got plenty of other cheap display options now, but sometimes you just need the old nought-through-nine, and in a big, visible package, to boot. For those circumstances, consider whipping up a set of these 3D-printed seven-segment displays.

The build consists of a 3D printed frame, with each segment containing two WS2812B addressable LEDs. Each 7-segment assembly is then wired so they can be daisy chained, passing on data to the next digit in the chain. Paper is used to diffuse the LEDs for a smoother look, and a white 3D printed cover is printed for each digit to further spread the light and give a clean finish.

Being based on the WS2812Bs, it’s easy to drive such displays with just about any microcontroller or GPIO-equipped Linux board out there. We love big, beautiful displays – and the more artistic, the better. Video after the break.

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3D Printing Without Support Material Thanks To An Additional Axis

January 16, 2021 by Lewin Day 52 Comments

Fused Deposition Modelling (FDM) 3D printers which squirt out molten plastic layer by layer are by far the most popular type in general use. Most machines extrude plastic through a nozzle above print bed, and struggle to produce parts with overhangs without using support material. However, a German team of researchers have recently come up with a solution.

In a prototype built by researchers at the Zurich University of Applied Sciences (ZHAW), a standard Cartesian printer has a third rotary axis added, upon which the nozzle can rotate. Additionally, the nozzle is angled at 45 degrees to the print bed, rather than the usual perpendicular setup. This allows layers of a print to be built up in such a way that support material is not needed for the vast majority of typical overhangs. This is particularly useful for hollow parts, where removing support material can be particularly difficult.

The team believes that such technology could be implemented on existing printers by way of a simple upgrade kit, and we can imagine a few experimenters will be champing at the bit to try it out. If you do, be sure to drop us a line. Alternatively, consider using a marker to make removing supports easier. Video after the break.

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