Repairs You Can Print: Take A Deep Breath Thanks To A 3D Printed Fume Extractor

January 29, 2018 by Sven Gregori 12 Comments

If you are a maker, chances are that you will be exposed to unhealthy fumes at some point during your ventures. Whether they involve soldering, treating wood, laser cutting, or 3D printing, it is in your best interest to do so in a well ventilated environment. What seems like sound advice in theory though is unfortunately not always a given in practice — in many cases, the workspace simply lacks the possibility, especially for hobbyists tinkering in their homes. In other cases, the air circulation is adequate, but the extraction itself could be more efficient by drawing out the fumes right where they occur. The latter was the case for [Zander] when he decided to build his own flexible hose fume extractor that he intends to use for anything from soldering to chemistry experiments.

Built around not much more than an AC fan, flex duct, and activated carbon, [Zander] designed and 3D printed all other required parts that turns it into an extractor. Equipped with a pre-filter to hold back all bigger particles before they hit the fan, the air flow is guided either through the active carbon filter, or attached to another flex duct for further venting. You can see more details of his build and how it works in the video after the break.

Workspace safety is often still overlooked by hobbyists, but improved air circulation doesn’t even need to be that complex for starters. There’s also more to read about fumes and other hazardous particles in a maker environment, and how to handle them.

Continue reading “Repairs You Can Print: Take A Deep Breath Thanks To A 3D Printed Fume Extractor” →

3D Print The Blasphemous Helicopter Part Known As A Jesus Nut

January 27, 2018 by Lewin Day 17 Comments

Today, when we say “Jesus nut”, we’re not referring to the people who spend their days proselytizing down at the mall. The term, likely spawned in the Vietnam war, refers to the main nut holding the rotors on to the mast of a helicopter which is in the shape of the Christian cross. If the “Jesus nut” was to fail, the rotors would detach from the craft, and there would be little for crews to do except to pray.

[Marius] was presented with a failed Jesus nut, though thankfully from an R/C helicopter, meaning there was no loss of life. A friend needed the part replaced for their FQ777 copter, so it was time to bust out the 3D printer and get to work.

The first step was to reconstruct the broken piece so it could be measured and then modeled in CAD software with the help of calipers to determine the original dimensions. What followed will be familiar to many 3D printing enthusiasts — a case of educated trial and error, experimenting with different filaments and print settings until a usable part was produced. [Marius] notes on the part’s Thingiverse page that they achieved the best print with an 0.2mm layer height, and printing two parts at once to allow the layers more time to cool during each pass. It was then a simple matter of tidying up the part with sandpaper and a drill bit before installing it on the vehicle.

[Marius] reports that the part was successful, being both strong enough to withstand the forces involved as well as having a fit that was just right to suit the rotor pin which needs to be able to turn freely within the Jesus nut. While they’re not always the right tool for the job, 3D printed replacement parts can sometimes surprise you. These prints that are used in repair work often don’t attract the same interest as printing cosplay armor, kinetic art, and low-poly Pokemon. But they quickly prove how transformative having a 3D printer, and the skills to use it, are. That’s why we’re running the Repairs You Can Print contest… take a few minutes to show off the really useful repairs you’ve pulled off with your 3D printer!

A Modern Take On The Crystal Radio

January 19, 2018 by Al Williams 20 Comments

We’ll admit that [3DSage] has a pretty standard design for a crystal radio. What we liked, though, was the 3D printed chassis with solderless connections. Of course, the working pieces aren’t 3D printed — you need an earphone, a diode, and some wire too. You can see the build and the finished product in the video below.

Winding the coil is going to take awhile, and the tuning is done with the coil and capacitance built into the tuning arrangement so you won’t have to find a variable capacitor for this build. There is a picture of the radio using a razor blade point contact with a pencil lead, so if you want to really scrimp on the diode, that works too, and you can see how at the end of the video.

We did like the use of cord ends from a sewing and craft supply store to serve as solderless springs. This would be a great item to print off a few dozen copies and use it for a school or youth group activity. You might want to pair it with an AM transmitter, though so the kids won’t be dismayed at what is playing on AM in most markets. [3DSage] uses a sink for ground — literally a kitchen sink. However, if you try this, make sure all the pipes are metal or you won’t get a good ground and you probably won’t pick up any stations.

We’d like to get some of those springs and make some other kind of starter projects with them like the kits many of us had as kids. This reminded us of the old foxhole radios, found during World War II.

Continue reading “A Modern Take On The Crystal Radio” →

3D Printed Propellers Take To The Skies

January 6, 2018 by Lewin Day 10 Comments

In the world of drones, propeller choice is key to performance. Selecting the right props can have a major effect on things like flight time, vibration, and a whole host of other factors. Thinking it might be fun to experiment, [RCLifeOn] decided to 3D print some props and head out for a fligh t.

The props are a fairly simple 3-bladed design, which were printed in both PETG and PLA. No major difference is noted between the two materials, and the quadcopter under test is able to fly with either. It was noted that the props perform particularly poorly in a crash, with all props failing even in the softest of crashes. We would recommend some eye (and body) protection when spinning these props up for the first time.

If you’re keen to try them out yourself, the STL file can be had here. The video notes that when printing 4 props, 2 must be reversed in the Y-axis to print a counter-rotating set of 4. The instructions used for creating propellers in Fusion3D are available here.

It’s a worthy experiment, and something we’d like to see more of. With a 3D printer, it’s possible to experiment with all manner of propeller designs, and we’d love to see the best and worst designs that are still capable of flight. We’ve also seen 3D printed props before, like this effort from [Anton].

Teaching Alexa To 3D Print

January 5, 2018 by Al Williams 21 Comments

Sometimes a gadget like Alexa or Google Home is a solution looking for a problem. Then the problem you’ve been looking for hits you square in the face. I’ve confessed before that I have an oscilloscope problem. I also have a microcontroller development board habit. It appears now I have too many 3D printers. I recently finished building my latest one, an Anet A8 I picked up on Black Friday. While calibrating it, I found myself juggling a screwdriver, a pair of pliers, and trying to operate the thing all at one time. I realized I had to come up with a better way.

I don’t know if it qualifies as an addiction yet, but I also have an Alexa in every room (although I call it “Computer” because I’m a Star Trek fan) and a Google Home device almost everywhere. Why can’t I get one of these assistants to operate my printer for me? What are assistants for, after all, other than telling Dad jokes?

You’d think adding voice control to a 3D printer would a bit difficult. With the right tools, it is actually pretty easy. Luckily those tools aren’t anything special… if you want a set up like mine, where Alexa controls your 3D printer, read on.

Continue reading “Teaching Alexa To 3D Print” →

Copyright Exception May Overrule Ability To Jailbreak 3D Printers

December 20, 2017 by Brian Benchoff 49 Comments

At the end of October, the US Patent and Trademark Office renewed a rule allowing anyone to ‘jailbreak’ a 3D printer to use unapproved filament. For those of you following along from countries that haven’t sent a man to the moon, a printer that requires proprietary filament is DRM, and exceptions to the legal enforceability DRM exist, provided these exceptions do not violate US copyright law. This rule allowing for the jailbreaking of 3D printers contains an exception so broad it may overturn the rule.

A few months ago, the US Copyright Office renewed a rule stating that using unapproved filament in a 3D printer does not violate US Copyright law. The language of this rule includes the wording:

‘The exemption shall not extend to any computer program on a 3D printer that produces goods or materials for use in commerce the physical production of which is subject to legal or regulatory oversight…”

This exception is extraordinarily broad; any 3D printers can produce aircraft parts (subject to FAA approval) and medical devices (subject to FDA approval). In effect, if a 3D printer has the ability to produce objects subject to regulatory oversight, the exception allowing the use of filament not approved by the manufacturer does not apply. Additionally, it should be noted that any object produced on a 3D printer that is subject to regulatory oversight is already regulated — there’s no reason to drag the Copyright Office into the world of 3D printed ventilation masks or turbine blades.

[Michael Weinberg], ‘legal guy’ for Shapeways and President of the Open Source Hardware Association has filed a petition with the US Copyright Office, asking the Office to eliminate this exception to the existing rule surrounding DRM and 3D printers. You are encouraged to submit a comment in support of this petition by March 14th.

DIY Cable Chain Looks Great, Stays Cheap

December 17, 2017 by Tom Nardi 50 Comments

If you’ve built a 3D printer, CNC, laser cutter, or basically any piece of electrical equipment that moves around, then you’ve run into the problem of securing the bundle of wires that such machines always require. The easy way out is to zip tie them all up into a tight harness or put them in commercially available wraps or sleeves, but these don’t really impart any mechanical strength on the wires. With repetitive motion it’s not unheard of to break a conductor or two, causing intermittent failures and generally leading to a painful diagnostic session trying to isolate the broken wire.

An alternative are what are generally referred to as “cable chains”. These are rigid enclosures for your wiring that not only keep things tidy, but give the wires the mechanical support necessary to prevent fatigue. Unfortunately, they are often many times more expensive than a simple wire wrap or pack of zip ties. But [Brad Parcels] has written into our tip line to share with us a sort of hybrid approach to wire management that has many of the same advantages as a traditional cable chain, but at a greatly reduced cost.

The key to the design is using the metallic tape from a cheap tape measure to give the bundle of wires some mechanical strength. As anyone who’s ever played around with a tape measure knows, if you bend the tape over into a U shape it will hold the bend even if you extend and retract it. Thanks to this principle, [Brad] realized that all he need to do was add some wire sleeves and he would have a cheap and effective way to keep his wiring neat and sag-free.

[Brad] punches holes in the tape to secure it to his 3D printed mounting arms, but really any method of securing the tape to the frame of your machine will work just as well. He then slides a cable sleeve over the tape itself to protect from any possibility of the edge of the tape nicking a wire, and then finally a larger wire sleeve over the entire assembly.

After running the wires between the two sleeves, heatshrink can be used on the ends to neatly close everything up. Just make sure you remember all your wires before you seal it, [Brad] learned that one the hard way. But overall, he reports this DIY cable chain arrangement has been working wonderfully in his machine, providing smooth and silent movement for only a few bucks.