THP Entry: A Holonomic Drive 3D Printer

August 5, 2014 by Brian Benchoff 59 Comments

holo

[Sugapes] always wanted to cut a few corners and build a really, really cheap 3D printer, but the idea of using linear actuators – pricing them, sourcing them, and the inevitable problems associated with them – scared him away. One day, he realized that moving in a plane in the X and Y dimensions wasn’t hard at all; cars and robots do this every day. Instead of moving a 3D printer bed around with rods and pulleys, [Sugapes] is moving his 3D printer around with wheels. It’s different, it’s interesting, and it’s the perfect project to show of his creativity for The Hackaday Prize.

The drive system [Sugapes] is using is called a holonomic drive system. In his build, three omnidirectional wheels are attached to continuous rotation servos, each of them mounted 120 degrees apart. The print bed is simply placed on these wheels, and with the right control algorithms, [Sugapes] can move the bed in the X and Y axes. With an extruder on a Z axis above the bed, this setup becomes a 3D printer with a theoretically unlimited XY build axis. Pretty clever, huh?

There are a few problems [Sugapes] will have to overcome to turn this project into a proper printer. The omnidirectional wheels aren’t the best at transferring movement to the bed, so a quartet of USB optical computer mice are being used for a closed loop system. [Sugapes] put up a video of his project, you can check that out below.

The project featured in this post is an entry in The Hackaday Prize. Build something awesome and win a trip to space or hundreds of other prizes.

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Milling Curved Objects With A G-Code Ripper

July 31, 2014 by Brian Benchoff 33 Comments

HaD Mouse

Milling and routing flat surfaces is pretty much the point of a CNC router, but how about curved surfaces? Auto leveling of hobby CNC machines and 3D printers is becoming commonplace, but Scorch Works is doing just the opposite: using a probe touch probe on a CNC machine to transform a G-Code file into something that can be milled on a curved surface.

The technique is pretty much the complete opposite of Autoleveller, the tool of choice for milling and routing objects that aren’t completely flat or perpendicular to the bed with a MACH3 or LinuxCNC machine. In this case, a touch probe attached to the router scans a curved part, applies bilinear interpolation to a G-Code file, and then starts machining.

The probe can be used on just about anything – in the videos below, you can see a perfect engraving in a block of plastic that’s about 30 degrees off perpendicular to the bed, letters carved in a baseball bat, and a guaranteed way to get your project featured on Hackaday.

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Clay 3D Printer Keeps It Simple

July 28, 2014 by Rich Bremer 23 Comments

Clay 3D Printer

Artist [Jonathan] has built a 3D printer specifically for printing in clay. The part count is kept to a minimum and the printer was designed to be made with basic tools and beginner skills. The intent was to not require access to a plastic 3D printer in order to build this printer. Although this build’s goal was clay printing, the extruder could certainly be swapped out for a typical plastic printer version.

This Delta uses quite a bit of MDF. The top and bottom plates are MDF, as are the bearing carriages and extruder mount plate. 12mm rods are solely responsible for the support between the top and bottoms plates as well providing a surface for the LM12UU linear bearings. These bearings are zip tied to the MDF bearing carriages. The 6 arms that support the extruder mount plate are made from aluminum tubing and Traxxas RC car rod-ends. NEMA17 motors and GT2 belts and pulleys are the method used to move the machine around.

Getting the clay to dispense was a tricky task. Parts scavenged from a pneumatic dispensing gun was used. If you are unfamiliar with this type of tool, think: Power Caulk Gun. Clay is fed into the re-fillable syringes and an air compressor provides the 30 psi required to force the clay out of the nozzle. The pressure alone controls the rate of clay flow so it is a little finicky to get the extrusion rate correct. Depending on the size of the final sculpture, 1 to 2mm diameter nozzles could be used. For larger work, 1mm layer height works well. For the smaller pieces, 0.5mm is the preferred layer height.

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Print Tasty Treats With MIT’s Ice Cream Printer

July 17, 2014 by Rick Osgood 10 Comments

Ice Cream Printer

Three MIT students decided that 3D printers just aren’t interesting enough on their own any more. They wanted to design a new type of printer that would really get young kids engaged. What’s more engaging to children than sugary treats? The team got together to develop a new 3d printer that prints ice cream.

The machine is built around a Solidoodle. The Solidoodle is a manufacturer of “accessible” 3d printers. The printer is enclosed inside of a small freezer to keep things cold during the printing process. On top of the machine is a hacked Cuisinart ice cream maker. The machine also contains a canister of liquid nitrogen. The nitrogen is used to blast the cream as it leaves the print head, keeping it frozen for the 15 minute duration of the print.

It sounds like the team ran into trouble with the ice cream melting, even with the liquid nitrogen added. For a single semester project, this isn’t a bad start. Be sure to watch the clip of the machine running below.

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THP Entry: TOME, The Portable 3D Printer

July 9, 2014 by Brian Benchoff 19 Comments

TOME Alright, 3D Printers exist. They’re machines you can simply buy for a few hundred dollars, set them on your desk, and have them start churning out plastic parts. A little pedestrian, isn’t it? How about something you can take into the field for a client, and print out some new parts right there? How about sending a printer to the latest humanitarian crisis? After all, all those humanitarian uses for 3D printers we’ve been hearing about won’t do any good without a 3D printer.

TOME is [Philip]’s attempt at portabilizing a 3D printer and also his entry into The Hackaday Prize. The preliminary goals for TOME are the ability to print for four hours on a single battery, an auto leveling bed, and an accessible hot end that’s easy to replace.

Already the design for TOME is rather interesting. The astute printer aficionado will notice there is no stepper motor on the X carriage. The task of moving the head in the X axis is taken care of by a stepper in the base, with a square shaft and set of gears moving everything back and forth.

With this odd yet ingenious motor setup, the entire printer is able to collapse in on itself, allowing it to be installed in a waterproof plastic case. That’s something you’re going to need if you’re taking a printer on the road.

The project featured in this post is an entry in The Hackaday Prize. Build something awesome and win a trip to space or hundreds of other prizes.

The Beginning Of The Age Of 3D Resin Printers

June 21, 2014 by Brian Benchoff 23 Comments

resin

For several years now, filament-based plastic printers have ruled the hobbyist market, with a new iteration on squirting plastic appearing on Kickstarter every week. SLA printers, with their higher resolution and historically higher price for raw materials, have sat in the background, waiting for their time to come.

Now, with the Sedgwick printer now available on Kickstarter, we may finally be seeing some resin printers make their way into hackerspaces and workshops the world over. Instead of other DLP projector-based resin printer where projector light shines up through the resin tank, the creator of the Sedgwick, [Ron Light] is doing things the old-fashioned way: shining the projector down onto the surface of the resin. He says it’s a simpler method, and given he’s able to ship a Sedgwick kit minus the projector for $600, he might be on to something.

There are a few other resin printers coming on the scene – the LittleSLA will soon see its own Kickstarter, the mUVe 1 is already shipping, and over on Hackaday Projects, the OpenExposer project is coming along nicely. All very good news for anyone who wants higher quality prints easily.

3D Printed Trays For Your Pick And Place Machine

June 12, 2014 by Adam Fabio 37 Comments

3dprintedPNPTray Pick and Place machines are one of the double-edged swords of electronics.They build your boards fast, but if you don’t have everything setup perfectly, they’ll quickly make a mess. A pick and place can’t grab a resistor from a pile and place it – so far only humans can pull that one off. They need parts organized and oriented in reels or trays.

[Parker Dillmann] had to load some parts, but didn’t have a tray for them, so he 3D printed his own. [Parker] works at a small assembly house in Texas. He’s working on a top secret design which includes FFC connectors. Unfortunately, the connectors shipped in pick and place unfriendly tubes rather than reels. If he couldn’t find a tray, [Parker] would have to hand place those connectors as a second operation, which would increase the time to build each board and leave more chances for mistakes.

Rather than place each part by hand, [Parker] got in touch with his friend [Chris Kraft] who is something of a 3D printing guru. [Chris] confirmed that a 3D printed tray would be possible, though the PLA he prints with was not static safe. That was fine for the connectors, but [Parker] was hoping to save some tray space by putting his PSOC4 chips in the printed tray as well.

[Parker] used SketchUp to design a tray that would fit his Madell DP2006-2 pick and place. He left .15mm clearance around the parts – just enough to cover any inaccuracies during printing, but not enough to throw off parts placement. He sent the STL file over to [Chris] who used Simplify3D to a create a Gcode file. [Chris] printed the tray at .2 mm layer height on his MakerGear M2 printer, and the results looked great. Would they be good enough for the pick and place machine?

[Parker] received the printed trays in the mail and loaded them with parts. The pick and place had no problem finding and placing the connectors, making this job a huge success. [Parker] even left room for the PSOC4 chips.He plans to paint the tray with anti-static paint before giving them at try.

We really like this story – it’s a perfect example of how 3D printers can speed up processes in manufacturing. Now that the basic design is done, creating new trays is a snap. Nice work [Parker] and [Chris]! Continue reading “3D Printed Trays For Your Pick And Place Machine” →