Fitting A CNC Machine, 3D Printer, And Vinyl Cutter In A Suitcase

September 29, 2012 by Brian Benchoff 25 Comments

Maker Faire NY is awash with new and interesting computer controlled tools, but the most unusual so far appears to be Popfab, a combination router, 3D printer, and vinyl cutter able to collapse down into a suitcase.

Popfab is the brainchild of [Nadya Peek] and [Ilan Moyer] of the MIT CADLAB. With interchangeable heads for routing PCBs, 3D printing, and vinyl cutting. A conventional machine of this capabilities would have motors all over the place, but [Ilan] used a CoreXY system to make the stepper motors stationary relative to the frame of the machine.

The electronics are standard Printrboard and Pronterface fare, but it’s still a remarkable build that also fits into a suitcase.

Pictures of the machine, the XY system (good luck wrapping your head around that, but I can tell you it relies on the differential movement of the two motors) and the lovely [Nadya] holding up the plastic extrusion head. We’ll get a video up ~~tomorrow.~~ after the break

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Turning 3D Prints Into Aluminum Castings

September 25, 2012 by Brian Benchoff 54 Comments

[Jeshua] needed a laser head attachment for a 5×10 foot CNC machine he’s working on. Because he has a 3D printer, [Jeshua] could easily print a laser mount and attach it to his CNC gantry, but that wouldn’t look very professional. Instead of decorating his gigantic machine with brightly colored plastic, he decided for a more industrial look by casting a laser head in aluminum using a 3D printed master.

[Jeshua] designed two parts for his laser cutter in OpenSCAD and printed them out on his 3D printer. A few bits of foam insulation were glued on to act as sprues, and an investment mold was made out of 1 part Plaster of Paris and 1 part playground sand.

After the mold had cured, [Jeshua] put is mold in a coffee can furnace to burn out the wax and foam. These hollow molds were placed in sand and the crucible loaded up with aluminum scrap.

The finished laser head fit his CNC machine perfectly – no small feat, considering [Jeshua] needed to take in to account how much the aluminum would contract after cooling. Not bad for one day’s work.

Turning A Shipping Container Into A 3D Printer

September 24, 2012 by Brian Benchoff 22 Comments

Built inside a 20-foot shipping container placed on its end, the Kamermaker – ” room maker” in Dutch – is one of the largest 3D printers we’ve ever seen. Able to print objects as big as 2 meter square and 3.5 meters high, the Kamermaker is designed to print huge objects including furniture, architectural elements, and even entire rooms.

The Kamermaker is a collaboration between Architectburo DUS and Utilimaker and the result of wanting to build the world’s largest 3D printer pavilion. Built inside a stainless steel-clad shipping container, the Kamermaker features a scaled-up version of the X, Y, and Z axes you’d find in any other 3D printer. The only change is a scaling up of current designs, allowing it to print small wind turbines covering its surface or, theoretically, a life-size TARDIS.

Because using traditional plastic filament would be prohibitively expensive, the Utilimaker team chose to extrude plastic pellets on the fly as it is used. There’s an excellent video of the filament extruder here along with a walk-through of the machine in operation after the break.

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3d Printer Filament Made Of Wood

September 21, 2012 by Brian Benchoff 24 Comments

Believe it or not, you can now squeeze wood through the nozzle of your 3D printer.

This new addition to the maker’s palette of 3D printer filaments comes from the mind of [Kai Parthy]. The new filament – going by the name Laywood – is a mix of recycled wood fibers and polymer binders that can be melted and extruded just like any other 3D printer filament.

Parts printed with Laywood have about the same properties as parts printed with PLA filament. One interesting feature of this material is the ability to add ‘tree rings,’ or a subtle gradation in color from a rich brown to a very nice beige. The color can be changed on the fly by setting the temperature of your printer’s hot end to 180° C for a light color, and 230° C for a darker color.

Judging from the ‘in action’ video of Laywood filament being pushed through a printer, the new wood-based filament works just the same as any other PLA or ABS plastic.

Outside eBay, there appears to be only one place to buy this filament. It’s not cheap at about €16/$20 USD per half kilogram, but hopefully that price will come down when it becomes more popular.

Video after the break.

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Introducing The Makerbot Replicator 2

September 19, 2012 by Brian Benchoff 78 Comments

A few short hours ago at press conference, Makerbot announced the release of their Replicator 2 3D printer.

The original Makerbot Replicator was released earlier this year at CES and regaled by the press as a quantum leap in home manufacturing (a quanta is actually very small, guys) with and option for dual extruders and a rather large build volume. The Replicator 2 takes the same formula and adds a powder coated steel frame, larger build volume (11.2″ x 6.0″ x 6.1″ or 28.5 x 15.3 x 15.5 cm) and a resolution so fine as to approach the realm of uber expensive 3D printers (100 microns or 0.004 inches).

Base price is $2200 USD for the single extruder model with no Makercare service plan. A dual-extruder Replicator 2X is slated to be released after the beginning of next year. This model will also handle ABS filament, although we can’t find anything that says the single-extruder Replicator 2 is only able to use PLA.

Even though the new Replicator 2 is rumored to be closed source, we’d really struggle to come up with a better 3D printer for a high school shop class, college CS and/or engineering department, or even a hackerspace.

This Hack Can Refill Your Stratasys 3D Printer

September 19, 2012 by Mike Szczys 92 Comments

[Dan] has his own Stratasys Dimension SST 768 3D printer. It’s a professional grade machine which does an amazing job. But when it comes time to replace the cartridge he has to pay the piper to the tune of $260. He can buy ABS filament for about $50 per kilogram, so he set out to refill his own P400 cartridges.

Respooling the cartridge must be quite easy because he doesn’t describe the process at all. But the physical act of refilling it doesn’t mean you can keep using it. The cartridge and the printer both store usage information that prevents this type of DIY refill; there’s an EEPROM in the cartridge and a log file on the printer’s hard drive. [Dan] pulled the hard drive out and used a Live CD to make an image. He loaded the image in a virtual machine, made some changes to enable SSH and zap the log file at each boot, then loaded the image back onto the printer’s drive. A script that he wrote is able to backup and rewrite the EEPROM chip, which basically rolls back the ‘odometer’ on how much filament has been used.

[Image Source]

Making Plastic Filament At Home

September 14, 2012 by Brian Benchoff 44 Comments

There’s one problem with the popularity of plastic-extruding 3D printers such as the RepRap and Makerbot; since they’ve become so popular, the price of plastic filament has skyrocketed over the past few years. Without a way to produce filament at a hackerspace or home lab, the price of 3D printed objects will remain fairly high. Project Spaghetti hopes to rectify that by building a machine to make plastic filament for 3D printers.

The folks behind Project Spaghetti – a loose amalgamation of makers going under the title of Open Source Printing, LLC – have successfully built a machine that is able to produce short lengths of plastic filament.

Early machines used a plunger to press small pellets of ABS plastic through a heated steel pipe to produce filament. There are a few problems with this approach, especially when the temperature is set to 480F, but the team was able to make a bit of filament with this design.

Although the team is using a piston to force melted plastic out of a nozzle, they do have a screw-drive ‘plan B’ in the works. This design should allow for continuous extrusion for theoretically endless reels of plastic filament, every RepRappers dream and a neat way to win 40 grand. Continue reading “Making Plastic Filament At Home” →