Fail Of The Week: The Metal Hot End Upgrade

My son, Patrick, has observed on more than one occasion that I do not like 3D printing. That may sound odd, because I built a printer back in 2012 and since then I’ve built a lot of printers and I currently have at least three in my lab. But Patrick correctly realized that I don’t actually enjoy printing things that I need. What I do enjoy is building, fixing and even more importantly improving the printers themselves. If you are reading Hackaday, you probably know how that is. This is the story of an upgrade gone bad, although the ending is happy enough. If you’ve ever thought about moving from a traditional hot end to an all-metal hot end, you might want to hear me out and maybe I can save you some trouble.

A few years ago, I picked up an Anet A8 for a really low price. As printers go, it is adequate. Not bad, but not amazing. But it is a fun printer because you really need to do some work on it to brace the acrylic frame and fix other shortcomings. I merrily improved the printer quite a bit over a relatively short period of time and I also bought a bunch of aluminum extrusion to rebuild the frame to the AM8 plans you can find on Thingiverse.

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3D Printer Add On Makes Sharp(ie) Colors

We’ve all seen 3D printed jigs that use a permanent marker to color filament as it goes into the hot end. [Sakati84] has a completely different idea. A holder on the print head can pick up one of several pens and use it to color the layer the hot end just laid down. In the video below, it looks like it works well and, although we imagine it will be a bear to calibrate on height, it seems like something you could replicate with nearly any conventional printer.

Logically, you print a layer with no pen in the holder and when you do pick up a pen, it will need to be somewhat lower than the print nozzle or else you’ll drag around in the fresh plastic.

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Injection Molds From Your 3D Printer

Last time we checked in with [CrafsMan] he had bought a benchtop injection molding machine. This time, he shows off how to 3D print molds. If you have ever had to spend to make tooling for injection molding, you’ll appreciate being able to make molds relatively inexpensively.

To test his workflow, [CrafsMan] created a little 3D figurine and brought it into TinkerCad. From there he created a mold and used Lychee Slicer to print it using resin.

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SOL75 Uses AI To Design Standard Mechanical Parts

[Francesco] developed a parametric design tool called SOL75 which aims to take the drudgery out of designing the basic mechanical parts used in projects. He knows how to design things like gears, pulleys, belts, brackets, enclosures, etc., but finds it repetitive and boring. He would rather spend his time on the interesting and challenging portions of his project instead.

The goal of SOL75 is to produce OpenSCAD and STL files of a part based on user requirements. These parameters go beyond the simple dimensional and include performance characteristics such as peak stress, rigidity, maximum temperature, etc. The program uses OpenSCAD to generate the geometries and a core module to evaluate candidate designs. In an attempt to overcome the curse of dimensionality, [Francesco] has trained an AI oracle to quickly accept or reject candidate solutions.

In the realm of parametric design aids, you have projects like NopSCADlib which dimensionally parameterize a large collection of common objects by numbers alone ( a 100 cm long, 6.35 mm diameter brass tube with 1.22 mm wall thickness ) or industry standard specifications ( a 10 mm long M3 socket head cap screw ). This approach doesn’t take into account whether the object will hold up in your application nor does it consider any 3D printing issues. At the other extreme, there are the generative design and optimization tools found in professional packages like Fusion 360 and SolidWorks which can make organic-looking items that are optimized precisely for the specified conditions.

SOL75 seems to fall in the middle, combine characteristics of both approaches. It gives you the freedom to select dimensional parameters and performance requirements, yet bounds the solution space by only offering objects that have been prepared ahead of time by domain experts — if you ask for an L-bracket, you’ll get an L-bracket and not something that looks like a spider web or frog leg.

Once you compile the design, SOL75 generates the OpenSCAD and/or STL files and a bill of materials. But wait — there’s more– it also makes a thorough design handbook documenting the part in great detail, including the various design considerations and notes on printing. Here is a demonstration link for an electronics enclosure which is pretty interesting. There is also an example of using SOL75 to make a glider, which you can read about on the Hackaday.io project page.

For now, [Francesco] has only made SOL75 available in a register-by-email online Beta version, as he’s still undecided on what form the final version will be. Do you have any success (or failure) stories regarding generative designs? Let us know in the comments below.

3D Print In The Air With A Little Software Support

We all love 3D printing, but printing anything that has an overhang requires support, right? Maybe not. [Create Inc] has a video showing some 3D prints that seem to hang impossibly in the air — not bridges, but loops just floating in the air. You can see the effect in the video below.

The first part of the post covers gcode basics. Around the 5:30 mark, [Create] talks about his inspiration: FullControl Gcode Designer. You can do a lot with this tool and it inspired [Create’s] similar web-based version.

The point of these tools is to make it easier to create gcode directly instead of using a slicer. You can think of it as assembly language for 3D printing — you can do almost everything in the high-level language — 3D models — but if you want ultimate control you use assembly language, or, in this case, gcode.

The original tool uses Excel which didn’t visualize the output directly and could not provide proper error checking. The new tool solves those problems and is much easier to use.

If you know gcode, you can do a lot of interesting things. You can even put a spring in your step.

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See-Through Carburetor Gives A Clear Demonstration

Carburetors have been largely phased out on most automobiles, but for a century they were the standard, and still are on many smaller engines. Armed with a high-speed camera and with the help of his father, [Smarter Every Day] investigates these devices by experimenting with a DIY see-through carburetor connected to a real engine.

The purpose of a carburetor is to mix gasoline and oxygen to the correct ratio for combustion inside the engine. Gasoline flow from the tank to the bowl, from where gets sucked into the venturi. The choke valve adjusts the amount of air entering the carb, while the throttle controls the amount of air-fuel mixture entering the engine. It appears that the carburetor was made from a resin 3D printed body and manifold, with an acrylic cover and PLA throttle and choke valves. It was attached to a single-cylinder engine.

The high-speed footage is incredible, and clearly shows the operation of the carburetor and makes it incredibly easy to understand. If you’re interested, he also uploaded a second video with almost 80 minutes of detailed footage.

[Smarter Every Day]’s infectious curiosity has led to numerous fascinating projects, including a supersonic baseball canon and the backward bicycle.

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Machine Extrudes Filament

We’ve seen a lot of homebrew filament extruders, but [Stefan] at CNC Kitchen shows off a commercial desktop filament extruder in his latest video, which you can see below. The 3DEVO extruder is pretty slick but at around $7,000-$8,000 we probably won’t rush out and buy one. We might, though, get some ideas from it for our next attempt to build something similar.

In concept, any machine that creates filament is pretty straightforward. Melt pellets and push them out of a nozzle. Cool the filament and wind it up. Easy, right? But, of course, the problems are all in the details. Die swell, for example, means you can’t just assume the nozzle’s hole size will give you the right size filament. Continue reading “Machine Extrudes Filament”