3D Print Finishing By Spraying Glazing Putty

May 10, 2022 by Dave Rowntree 19 Comments

Finishing off 3D prints is a labour-intensive process, and getting a good looking, smooth surface suitable for painting takes a lot of time and plenty of practice. Deeper printing layer lines or minor surface defects can be smoother over with a variety of materials, from putties to resins, but the deeper the defect, the thicker the filler and that takes it toll on the surface details – smoothing those out and making fine details less distinct. [Darkwing dad] has another solution that looks pretty easy to achieve, by mixing acetone with glazing putty it can be airbrushed over the print surface in one go. After a little experimentation with the ratio of putty to acetone, a wide open nozzle and a low pressure, it was found that a nice even spray could be achieved. Importantly it dries in just a few minutes, enabling multiple coats to be applied in a short space of time.

Once sufficient thickness has been applied, the coating can easily sanded to get a smooth result with the worst of the gaps filled, and the layer lines nicely hidden. The final part of the filling process is more typical, with a few coats of filler primer applied straight from a rattle can, followed by a light sand and you’re good for painting.

We’ve covered smoothing 3D prints practically as long as we’ve been covering 3D printing itself, and there are multiple ways to do this, depending on the filament material, your budget and you tolerance for noxious fumes. Here’s a guide for smoothing using UV curable resins, using a special smoothable filament with IPA, and finally if this is just too fancy, smelly or expensive, just whip out the old butane torch and smooth those prints with good old fashioned fire.

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Maze Bolt Toy By Lost PLA Casting

May 5, 2022 by Anne Ogborn 8 Comments

Maze bolts, a bolt which has a maze along its shaft traversed by a pin on its nut, are great fun. Here’s a really beautiful metal version by [Robinson Foundry], made by a process more makers should know about – lost PLA casting.

His basic method is to 3D print in PLA, and then use more or less the same process as lost wax casting.

He 3D printed the part, along with the sprues and risers that go along with casting, in PLA, then dipped the parts in slurry ten (10) times. He heated in a kiln to 500°F (260°C), the PLA melted and ran out or burned away. With the PLA gone, after repairing a few cracks, he raised the temperature to 1500°F (815°C) and vitrified the slurry into a ceramic. He now had molds.

The nut is bronze. The bolt is aluminum. He poured the metal with the molds hot, held in heated sand, so the metal can flow into all the small details. The rest of the project is just cleanup, but we learned that you can vary the finish produced by glass bead blasting just by varying the air pressure.

A great demo of a useful technique and a fun toy at the end.

We covered a great technique for doing lost PLA casting using a microwave.

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A Universal, Non-planar Slicer For 3D Printing Is Worth Thinking About

April 23, 2022 by Donald Papp 28 Comments

One may think that when it comes to 3D printing, slicing software is pretty much a solved problem. Take a 3D model, slice it into flat layers equal to layer height, and make a toolpath so the nozzle can create those layers one at a time. However, as 3D printing becomes more complex and capable, this “flat planar slicing” approach will eventually become a limitation because a series of flat slices won’t necessarily the best way to treat all objects (nor all materials or toolheads, for that matter.)

How a 20 mm cube looks when sliced in a cone-shaped plane.

[René K. Müller] works to re-imagine slicing itself, and shows off the results of slicing 3D models using non-planar geometries. There are loads of pictures of a 20 mm cube being sliced with a variety of different geometries, so be sure to give it a look. There’s a video embedded below the page break that covers the main points.

It’s all forward-thinking stuff, and [René] certainly makes some compelling points in favor of a need for universal slicing; a system capable of handling any geometry, with the freedom to process along any path or direction. This is a concept that raises other interesting questions, too. For example, when slicing a 20 mm cube with non-planar geometries, the resulting slices often look strange. What’s the best way to create a toolpath for such a slice? After all, some slicing geometries are clearly better for the object, but can’t be accommodated by normal hot ends (that’s where a rotating, tilted nozzle comes in.)

Such worries may not be an issue for most users at the moment, but it’s worth trying to get ahead of the curve on something like this. And lest anyone think that non-planar slicing has no practical purpose, we previously covered [René]’s demonstration of how non-planar slicing can reliably create 90° overhangs with no supports.

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Car Hacker Hacks Lawn Care Carb Into Hot Rod Car

April 21, 2022 by Ryan Flowers 45 Comments

Internal combustion engines have often been described (quite correctly) as air pumps, and because of this nature, they tend to respond very well to more air. Why? Because more air means more fuel, and more fuel means more power- the very nature of hot rodding itself. [Thunderhead289] is an accomplished car hacker, and he’s decided to take things the opposite direction: Less air, less fuel… more mileage? As you can see in the video below the break, [Thunderhead289] has figured out how to mount a single barrel carburetor from a lawn mower to the four barrel intake of a Ford 302– a V8 engine that’s many times larger than the largest single cylinder lawnmower!

The hacks start not just with the concept, but with getting the carburetor installed. Rather than being a downdraft carburetor, the new unit is a side draft, with the float bowl below the carb’s venturi. To mount it, a 3d printed adapter was made, which was no small feat on its own. [Thunderhead289] had to get quite creative and even elevate the temperature of his workshop to over 100 degrees Fahrenheit (38 Celsius) to get the print finished properly. Even then, the 34 hour print damaged his Ender printer, but not before completing the part.

The hackery doesn’t stop there, because simply mounting the carburetor is only half the battle. Getting the engine to run properly with such a huge intake restriction is a new task all its own, with a deeper dive into fuel pressure management, proper distributor timing, and instrumenting the car to make sure it won’t self destruct due to a poor fuel mixture.

While [Thunderhead289] hasn’t been able to check the mileage of his vehicle yet, just getting it running smoothly is quite an accomplishment. If silly car hacks are your thing, check out [Robot Cantina]’s 212cc powered Insight and how they checked the output of their little engine. Thanks to [plainspicker] for the tip!

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The Honda Takedown: How A Global Brand Failed To Read The Room

April 21, 2022 by Jenny List 141 Comments

Perhaps the story of the moment in the world of 3D printing concerns a Japanese manufacturer of cars and motorcycles. Honda has sent a takedown notice requesting the removal of models starting with the word “Honda” to the popular 3D printing model repository site Printables. It’s left in its wake puzzlement, disappointment, and some anger, but what’s really going on? Perhaps it’s time to examine what has happened and to ponder what it means for those who put online printable parts and accessories for cars or any other item manufactured by a large corporation.

If You Make Something, What Rights Do You Have?

Soichiro Honda with his 1964 Formula 1 car — Soichiro Honda, famous for being an engineer rather than a serial litigator. Roderick Eime, CC BY 2.0.

The story is that as far as we can glean from reports online, the takedown notice was sent only to Printables by the European arm of Honda, and was pretty wide-ranging with any Honda-related model in its scope. Printables complied with it, but as this is being written there are plenty of such models available from Thingiverse and other model repository sites.

Anyone who makes a career in content creation has by necessity to have a working knowledge of copyright and intellectual property law as it’s easy for the unwary to end up the subject of a nasty letter, so here at Hackaday while we’re not lawyers this is a subject on which we have some professional experience. What follows then is our take based on that experience, our view on Honda’s motivation, and whether those of you who put up 3D models have anything to worry about. Continue reading “The Honda Takedown: How A Global Brand Failed To Read The Room” →

3D Printing Pills All At Once

April 14, 2022 by Al Williams 7 Comments

To the uninitiated, it might seem like a gimmick to 3D print pharmaceuticals. After all, you take some kind of medicine, pour it in a mold, and you have a pill, right? But researchers and even some commercial companies are 3D printing drugs with unusual chemical or physical properties. For example, pills with braille identification on them or antibiotics with complex drug-release rates. The Universidade de Santiago de Compostela and the University College London can now 3D print pills without relying on a layer-by-layer approach. Instead, the machine produces the entire pill directly.

According to a recent report on the study, there are at least two things holding back printed pills. First, anything medical has to go through rigorous testing for approval in nearly any country. In addition, producing pills at typical 3D printing speeds is uneconomical. This new approach uses multiple beams of light to polymerize an entire tank of resin at once in as little as seven seconds.

With 3D printed drugs, it is possible to tailor release profiles for individual cases and make hybrid drugs such as a French drug that joins anticancer drugs with another drug to manage side effects. Is this a real thing for the future? Will doctors collect enough data to make it meaningful to tailor drugs to patients? Will regulators allow it? For hybrid medicine, is there really an advantage over just taking two pills? Only time will tell.

Sure, technology can help dispense pills. We know, too, that 3D printing can be useful for prostheses and medical devices. We aren’t so sure about pharmaceuticals, but in the meantime you can already order custom-printed vitamins.

Reducing Warping In Metal 3D Prints

April 13, 2022 by Al Williams 9 Comments

We are used to dealing with warping when printing with thermoplastics like ABS, but metal printers suffer from this problem, too. The University of Michigan has a new technology, SmartScan, that promises to reduce this problem. You can see a video about the technique, below.

The idea is to develop a thermal model of the printed part before laser sintering and then move the laser in such a way that heat doesn’t accumulate. The video shows how engraving metal in the traditional way causes the metal to warp as the laser heats up areas. Using the SmartScan thermal model, they were able to reduce deformation by almost half.

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