Metal 3D Printing Gets Really Fast (and Really Ugly)

February 17, 2024 by Donald Papp 8 Comments

The secret to cranking out a furniture-sized metal frame in minutes is Liquid Metal Printing (LMP), demonstrated by researchers at the Massachusetts Institute of Technology. They’ve demonstrated printing aluminum frames for tables and chairs, which are perfectly solid and able to withstand post-processing like drilling and milling.

The system heats aluminum in a graphite crucible, and the molten metal is gravity-fed through a ceramic nozzle and deposited into a bed of tiny 100-micron glass beads. The beads act as both print bed and support structure, allowing the metal to cool quickly without really affecting the surface. Molten aluminum is a harsh material to work with, so both the ceramic nozzle material and the glass beads to fill the print bed were selected after a lot of testing.

This printing method is fast and scalable, but sacrifices resolution. Ideally, the team would love to make a system capable of melting down recycled aluminum to print parts with. That would really be something new and interesting when it comes to manufacturing.

The look of the printed metal honestly reminds us a little of CandyFab from [Windell Oskay] and [Lenore Edman] at Evil Mad Scientist, which was a 3D printer before hobbyist 3D printers or kits were really a thing. CandyFab worked differently — it used hot air to melt sugar together one layer at a time — but the end result has a similar sort of look to it. Might not be pretty, but hey, looks aren’t everything.

(Update: see it in action in this video, which is also embedded just below. Thanks [CityZen] for sharing in the comments!)

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3D Printed Basketball Could Be A Game Changer

February 11, 2024 by Kristina Panos 23 Comments

Basketball has changed a lot over the years, and that goes for the sport as well as the ball itself. While James Naismith first prescribed tossing soccer balls into peach baskets to allow athletes to stay in shape over the winter, today, the sport looks quite different both rule-wise and equipment-wise.

An early basketball. Image via Wikipedia

The basketball itself has gone through a few iterations. After the soccer ball came a purpose-built leather ball with stitches and a rubber bladder inside. The first molded version came in 1942, although most balls continued to be made of leather, especially for indoor-only use. Today, the NBA still uses leather-clad balls, but that could change. Wilson, the official supplier of NCAA postseason tournament balls, has developed a 3D-printed basketball that never needs to be inflated.

Much like a regular ball, the Wilson Airless Gen1 has eight lobes, bounces like you’d expect, and can be palmed, provided your hand is big enough. We would argue forcefully that it is far from airless, though we do get the point. According to TCT Magazine, the ball “nearly fits” the performance specs of a regular basketball, including weight, size, and rebound. This may not be good enough for the NBA today, but we doubt innovation over at Wilson has stopped abruptly, so who knows what the future holds?

Interested in trying one out? You may be better off trying to design and print one yourself. The limited-edition ball will be available on February 16th at Wilson.com for the low, low price of $2,500. It would probably pair well with the can’t-miss robotic hoop. Or, pair it with a giant 3D-printed hand for display purposes.

Main and thumbnail images via Wilson Sporting Goods

3D Printing Silicone Parts

February 8, 2024 by Al Williams 6 Comments

Silicone is a useful material for many purposes. Traditionally, creating something out of silicone required injection molding. That’s not difficult, but it does require a good bit of setup. As [Formlabs] points out in a recent video, there are at least three other routes to create silicone parts that utilize 3D printing technology that might fit your application better, especially if you only need a few of a particular item. You can see the video below.

The three methods are either printing silicone directly, printing a mold, casting silicone, or using high-performance elastomers, which are very silicone-like. Of course, as you might expect, some of this is aimed at prompting some of [Formlab’s] products, like a new silicone resin, and you can’t blame them for that.

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3D Printed Screw Compressor Revisited

January 22, 2024 by Al Williams 12 Comments

[Indeterminate Design] tried to 3D print a screw compressor some time ago but wasn’t satisfied with the result. He’s trying it again, and you can check it out in the video below. You can also download the 3D printable files.

This isn’t a 3D-printed keychain. The screw threads have to mesh with a small space between them, and the design is not trivial. Even if you don’t want to build your own, the look inside the engineering behind these devices is interesting, and there is quite a bit of background about how the rotor’s shapes are optimized.

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There Are Stradi-various Ways To Make A Violin, And This Is One

January 8, 2024 by Kristina Panos 14 Comments

We’ve always said that if we had enough money, we’d have a large room that housed every musical instrument we’ve ever been even mildly interested in. While that dream may never come to pass, it would be far more likely to happen if many of the instruments could be 3D-printed, like this electric violin.

We really like this compact design, which mimics a headless guitar with the tuning pegs down by the bridge. [Carmensr] started with a model on Thingiverse, which uses violin strings wound around electric guitar tuners instead of wooden friction pegs. To further the guitar comparison, the three-piece neck contains a truss rod of sorts.

So how does it work, though? The magic is in the special bridge, which contains a piezo element. The bridge picks up the strings’ vibrations and sends them to a little pre-amplifier, which creates a signal that can then be used by a program like Audacity or connected directly to a speaker. Be sure to give it a listen in the video after the break.

Of course, there’s no reason not to design and print acoustic violins. It would be fun to experiment with different filaments for different sounds.

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[Thomas Sanladerer] Gets New Threads

January 6, 2024 by Al Williams 18 Comments

If you do much practical 3D printing, you eventually need some sort of fastener. You can use a screw to bite into plastic. You can create a clearance hole to accommodate a bolt and a nut or even build in a nut trap. You can also heat-set threaded inserts. Which is the best? [Thomas] does his usual complete examination and testing of the options in a recent video you can watch below.

[Thomas] uses inserts from [CNCKitchen] and some cheap inserts for 3D printing and some for injection molding. There are differences in the configuration of the teeth that bite into the plastic. [Thomas] also experimented with thread adapters that grab a 3D-printed thread.

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3D Printing Stacks

December 24, 2023 by Al Williams 3 Comments

There is a big difference between building one of something and building, say, 100 of the same item. It isn’t surprising, then, that 3D printing in bulk differs from printing one object at a time. Of course, filling up your build plate is not a new idea. But [Keep Making] wants to encourage you to think in three dimensions and fill up your build volume in the Z axis, as well.

When you fill your X and Y axes, it is easy to see how the parts separate. But with stack printing, you must separate the parts from different layers. Each part has a single-layer gap, and the top surfaces are ironed for a better finish. Sometimes the prints may stick, and the video shows how to use a screw to pop off recalcitrant prints. The technique produces one side that isn’t as nice a finish as the other side, but it isn’t bad, and for many applications, you don’t care, anyway.

Before you get too excited about your own designs, you might try a simple test file and get your print settings dialed in. Obviously, if you need just two or three copies of something small, it is easier to step and repeat them across the build surface. But if you need to maximize your throughput or make multiple copies of large objects, this might be the technique for you.

Looks like an interesting technique that doesn’t require you to do anything strange like, say, waterproof your printer. No strings attached.

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