Makerbot Printer Reborn As PCB Engraver

June 25, 2018 by Steven Dufresne 14 Comments

Makerbot 3D printers were among the first to hit the market, so it makes sense that old and broken ones now litter the shelves of hackerspaces and home workshops alike. Rather than throw his one out, [Foaly] saw an opportunity to convert it to some sort of CNC machine. Given its lack of inherent rigidity and relatively weak motors, he opted to make a low-impact circuit board engraver which he appropriately calls the MakerbotCNC. We like the thought he put into this project, and it was clearly backed by plenty of experience.

Fortunately, his Makerbot Replicator 2 stemmed from a time when MakerBot was more open, meaning he could control the machine using a simple, open library. A little more open software handled his conversion of Gerber files to G-code. First tests drawing with a pen were successful, so he moved on to the carving head. He opted for an inrunner brushless motor to minimize dust getting into the motor but since these motors have a tendency to heat up he had to add fans to cool it. That still didn’t stop the heat from melting and bending his attempt at a 3D printed PLA carriage, so he switched it to a laser-cut MDF board to fix it. Finding the right collet proved tricky but eventually, he found the perfect fit was a collet clutch normally used to couple flex shafts to RC boat motors.

The result, as you can see was worth it. Using shallow passes, he can even cut carbon fiber parts.

While [Foaly] didn’t opt to replace more parts and go for a more powerful CNC, check out this 3D printer to CNC conversion which can cut wood, acrylic, and even aluminum.

The Tantillus, Reborn

May 30, 2018 by Brian Benchoff 34 Comments

In the beginning, around 2011 or thereabouts, there was an infinite variety of designs available for anyone to build their own 3D printer. There were Mendels, some weirdos were actually trying to build Darwins, and deltas were starting to become a thing. In the years since then, everyone just started buying cheap Prusa clones and wondering why their house burnt down.

One of the most innovative printers of this era was the Tantillus. It was a small printer, with the entire frame fitting in a 250mm square, but still able to print a 100mm cube. You could print the entire printer, and it was adorable. Face it: most of your prints aren’t bigger than 100mm unless you’re purposely printing something huge, and having a low moving mass is good.

The Tantillus has fallen by the wayside, but now it’s back. The Tantillus R — the ‘R’ means ‘reborn’ — is the latest project to take the design goals of the original Tantillus and bring it into the era of the modern RepRap ecosystem. (German, Google Translatrix, but the English translation of all the documentation is in the works),

Of note in this new design, the Tantillus R is still using shafts driven with high-test fishing line, driven by steppers and belts. The R version is getting away from the J-head, but in the interests in keeping the moving mass down, the hotend is a Merlin. This might seem an especially odd choice in the age of all-metal hotends, but again the goal is to keep moving mass down. As you would expect from a modern 3D printer, there’s support for a heated bed, you can plug a Raspberry Pi into it for Octoprint, and in true RepRap fashion, most of the parts are printable.

While the era of self-build 3D printers is probably over — you can’t compete with the cheap Chinese firestarters on price — the Tantillus R is a great project that retains the spirit of the RepRap projects while adding a few modern niceties and can still produce some impressive prints.

3D Printing Air Quality Study

May 13, 2018 by Al Williams 18 Comments

You’ll often hear about some study in the media and then — on examination — find it doesn’t really apply to your situation. Sure, substance X causes cancer in rats, but they ate 8 pounds of it a day for a decade. That’s why we were glad to see [Chuck] post a series of videos about 3D printing air quality based on his practical experience. You can see the summary video, below.

[Chuck] is quick to point out that he isn’t a doctor or even a chemist. He also admits the $100 meter from IGERESS he is using isn’t necessarily high-quality test gear. Still, the data is a good guideline and he did get repeatable results.

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3D Printed Bicycle Tire Not Full Of Hot Air

May 7, 2018 by Al Williams 29 Comments

To show off its new TPU filament called PRO FLEX, BigRep GmbH posted a video showing a 3D printed bike tire that uses a flexible plastic structure instead of air. The video shows them driving the bike around Berlin.

According to the company, the filament will allow the creation of a large number of industrial objects not readily built with other types of plastic. Their release claims the material has high temperature resistance, low temperature impact resistance, and is highly durable. Applications include gear knobs, door handles, skateboard wheels, and other flexible parts that need to be durable.

The material has a Shore 98 A rating. By way of comparison, a shoe heel is typically about 80 on the same scale and an automobile tire is usually around 70 or so. The hard rubber wheels you find on shopping carts are about the same hardness rating as PRO FLEX.

Obviously, a bicycle tire is going to take a big printer. BigRep is the company that makes the BigRep One which has a large build volume. Even with a wide diameter tip, though, be prepared to wait. One of their case studies is entitled, “Large Architectural Model 3D Printed in Only 11 Days.” Large, in this case, is a 1:50 scale model of a villa. Not tiny, but still.

We’ve looked at other large printers in the past including 3DMonstr, and the Gigimaker. Of course, the latest trend is printers with a practically infinite build volume.

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3D Printed Tank Scores Suspension

May 3, 2018 by Lewin Day 10 Comments

Tanks are highly capable vehicles, with their tracks giving them the ability to traverse all manner of terrain at speed. An important part of a tank is its suspension setup, without which its treads are far less capable. When [Ivan] began work on his 3D printed tank project, he couldn’t ignore the comments. His tank would need a suspension system.

The tank build itself is impressive, consisting almost entirely of 3D printed components held together with off-the-shelf bearings and threaded rod. [Ivan] retools the tank from the beginning to fit a pivoting suspension system which is surprisingly simple in its design, yet capable in operation. Particularly impressive are the 3D printed springs, which [Ivan] tunes the stiffness of to suit the weight of the vehicle.

It’s a build that shows just how far you can go when you master the basics of 3D printing and mechanical design. It doesn’t take a lot of advanced theory to design cool things, just a willingness to learn and experiment and the right set of tools behind you. [Ivan]’s tank treads are worth taking a look at, too. Video after the break.

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Smooth PLA Through The Fire And Flames

May 3, 2018 by Lewin Day 17 Comments

3D printing makes it easy to produce complex geometries, but the fused deposition methods generally create parts with poor surface finish, largely due to the layers being highly visible in the finished part. There are a wide variety of ways to deal with this, often involving sanding parts after production, or the use of fillers and paints. [XerotoLabs] has another solution. (YouTube, video below the break.)

To smooth the parts, a butane torch is pressed into service. The flame temperature is kept fairly low, and the torch is used almost like a brush to evenly apply heat to the surface of the part. As the PLA reaches its melting temperature, surface tension helps to smooth the part out. This is very similar to flame polishing which is commonly used in the fabrication of acrylic plastics.

It is a technique that requires some finesse – too much heat or focus on a single area, and you’re liable to end up with a molten plastic blob instead of a nice shiny finished part. Precautions must also be taken to avoid burning yourself or your workshop to the ground. But it’s a useful tool to have in your kit when you’re producing PLA parts that you want to look their best.

We’ve seen other techniques for smoothing PLA, too – the solvent method is particularly interesting. Continue reading “Smooth PLA Through The Fire And Flames” →

Parametric Hinges With Tinkercad

April 23, 2018 by Al Williams 7 Comments

Simple tools are great, but sometimes it is most convenient to just use something easy, and since it gets the work done, you don’t try out some of the other features. Tinkercad is a great example of that kind of program. It is actually quite powerful, but many people just use it in the simplest way possible. [Chuck] noticed a video about making a 3D-printed hinge using Tinkercad and in that video [Nerys] manually placed a bunch of hinges using cut and paste along with the arrow keys for positioning. While it worked, it wasn’t the most elegant way to do it, so [Chuck] made a video showing how to do it parametrically. You can see that video below, along with the original hinge video.

There are really two major techniques [Chuck] shows. First, he adds the necessary pieces to create the hinges to the Tinkercad toolbox. That makes it really simple to add them to any of your future designs. Second, he uses a combination of numeric parameters and duplication to quickly and precisely place the hinge components across another object — in this case a Batman logo.

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