3D Printering: The Combo Machines Cometh

August 28, 2013 by Brian Benchoff 30 Comments

There’s only so many ways to squeeze hot plastic out of a nozzle, and eventually witnessing the explosion of 3D printer designs over the past few years gets just a little repetitive. What then, is someone who dreams of a technological utopia, Star Trek replicators, and making a few bucks off a Kickstarter to do?

The answer, of course, is a combo machine. Where the Repraps, Makerbots, and the very high-end Stereolithography machines can only do additive manufacturing by laying down plastic or resin layer by layer, these combo machines can also remove material, be it plastic, wood, or metals such as brass or aluminum.

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NESPo: Another 3D Printed Portable NES

August 19, 2013 by Marsh 6 Comments

portableNESSide2

Grab your favorite cartridge and violently blow into the end, because [Dave Nunez] is sending us on a nostalgia trip with his 3D printed portable NES. He takes the typical route of chopping up a Nintendo on a chip (NOAC) retro machine rather than sacrifice a real NES, and opts for a NiMH battery over lithium (which isn’t a bad idea; they can burst into flames if you charge them incorrectly). The battery life is, however, tolerable: 2.5 to 3 hours.

All the components are packed into a custom-made 3D printed PLA enclosure, which [Dave] kindly shares on thingiverse. He also decided to 3D print each of the buttons and their bezels/housings, which he then topped off by cutting acrylic sheets that seal up the front and back. As a final touch, [Dave] slips in some custom art under the acrylic and mounts a printed LED nameplate in the corner.

We’ve seen [Dave’s] work at Hackaday before, when he built a one-size-fits-all-consoles arcade controller.

Dual Extruders In The Space Of One Stepper Motor

August 10, 2013 by Brian Benchoff 76 Comments

The new hotness in 3D printers is – and has been for a while – dual extrusion. With two extruders and the requisite filament supply, it’s possible to print objects in two colors or two different materials. There’s a problem with this setup, though: each extruder requires a separate motor, greatly reducing the print area should you want to print in two or more colors. [Carl] and [Brian] think they have the solution to this with their dual extruder that is powered by one stepper motor.

As you can see from the pic above, the idea is relatively simple. Two strands of filament are fed past one gear attached to a stepper motor. Each strand is moved into the hot end through two idler gears and side of the extruder feeds into the hot end is determined by the rotation of the motor. It’s really one of those, “why didn’t I think of that” ideas.

[Carl] and [Brian] are also offering a quad extruder, a dual-sized extruder able to pump four different filaments onto a printer bed. With this, we expect some people to experiment with CMYK (or CMYW) prints, truly turning any 3D printer into a machine that prints full color parts.

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The Tiniest Arcade Cabinets You’ve Ever Seen

July 11, 2013 by Brian Benchoff 25 Comments

After perusing Amazon one day, [Dave] found a very interesting piece of kit: a small, 1.5″ digital picture frame. They’re not very complex, just an LCD, a few buttons to cycle the picture, and a battery to keep everything portable. He decided the best use of this tech would be a tiny arcade cabinet, featuring screen shots of the best games a darkly neon lit arcade of the late 80s had to offer.

After sourcing a few of these digital picture frames on eBay, [Dave] set to work disassembling the frames and designing a custom enclosure. He wanted a few specific features: controls in the right place, replaceable sides, and the glowing red eyes of a coin acceptor slot. [Dave] whipped a model up in OpenSCAD and sent the parts over to his printer.

The controls for the digital picture frame were connected to a quartet of tact switches on the control panel, and a red LED provides the glow from the coin acceptor. With a USB plug and the frame’s memory loaded up with screen shots, [Dave] has a fabulous desk toy.

All the relevant files are up on Thingiverse if you’d like to build your own.

We’ve Found The Awesome Singularity

July 9, 2013 by Brian Benchoff 32 Comments

tardis

Yes, that’s exactly what you think it is. A Transformer. That transforms into the TARDIS.

This masterpiece of pop culture is the work of [Nonnef] over on Instructables. After the inspiration to create this work of art struck, [Nonnef] started modeling this Transformer and TARDIS in clay to make everything fit together just right. After a good bit of 3D modelling, the Doctor’s robotic wife was ready for printing.

If you’re going to print one of these for yourself, be prepared for a very long print. [Nonnef] says the latest version took about 30 hours on his RepRap with a .35 mm nozzle. In the end nearly the entire Transformer came directly from a 3D printer, the only additional parts needed being a pen spring and a small screw. Paint is, of course, optional.

All the files are available on the Instructable.

3D Printed Bike Shifter

July 7, 2013 by Brian Benchoff 26 Comments

Shifter

[Rich] is embarking on a fairly long bike trip in a few weeks – Seattle to Portland – and thought including some 3D printed gear on his ride would be a fun endeavor. His first idea was a printed belt drive, but the more he looked at that idea the less realistic it seemed. He finally hit upon the idea of creating a 3D printed bike shifter, and after an afternoon of engineering and printing, the shifter ended up working very well.

[Rich]’s shifter is actually a friction shifter. Instead of ‘clicking’ into position, this type moves the derailleur gradually. It’s much more tolerant of slight misalignment, and most touring bikes – the type that would embark on long journeys along the coast of the Pacific northwest – have these types of shifters.

Total printing time was about one and a half hours, and was attached to [Rich]’s bike with off-the-shelf hardware. He’s already put about 150 miles on his custom designed shifter with no signs of failure.

Easily 3D Print Mesh Screens

June 29, 2013 by Mike Szczys 22 Comments

easy-way-to-3d-print-mesh-screens

If you need a way to make openings in your project enclosures look nice just head on over to the 3D printer. In the image above [Alfred] is showing off the result of his Slic3r hack for printing mesh grills.

It’s important to note that you need to make sure you’re using Slic3r version 0.9.8. This won’t work with newer versions because starting with 0.9.9 the software will add a raft to the bottom of your design.

The grill can be in any shape you desire. It starts by modelling this outline, then extruding the edges downward the same distance as your desired mesh thickness. After importing the design file into Slic3r [Alfred] uses the support material settings to choose this honeycomb design. He then sets the fill density to zero. This means the design will not be printed at all, only the fill material, resulting in these honeycomb screens.

Slic3r’s a fantastic piece of software. Check out this interview with Slic3r’s lead developer.