3D Printing With A Twist

When we think about sending an STL off on the Internet for processing, we usually want someone to print it for us or we want mesh repair. But [Chuck] found an interesting project on GitHub from [Andrew Sink] that will let you add a variable amount of twist to any STL and then return it to you for printing or whatever else you use STLs for. If you don’t get what we mean, check out the video below.

The site that does the work initially loads a little gnome figure if you are too lazy to upload your own model. That’s perfect, though, because the little guy is a good example of why you might want to twist a model. With just a little work, you can make the gnome look in one direction or even look behind him.

[Chuck] shows how to use the tool for artistic effect by twisting his standard cube logo. The result is something that looks like it would be difficult to create, but could hardly be easier. The tool lets you rotate the object, too, so you can get the twist effect in the right orientation for what you want to accomplish. A great little tool for making more artistic 3D prints without learning new software. If you want some fun, you can try the version that uses sound from your microphone to control the twist.

If you’d rather twist in CAD, we can help. If you really want artsy 3D printing, you probably need to learn Blender.

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3D Printing With Sublime Sublimation

[Teaching Tech] got an interesting e-mail from [Johan] showing pictures of 3D prints with a dye-sublimated color image on the surface. Normally, we think of dye sublimation, we think of pressing color pictures onto fabric, especially T-shirts. But [Johan] uses a modified Epson inkjet printer and has amazing results, as you can see in the video below.

The printers use separate tanks for ink, which seems to be the key. If you already have an Espon “tank” printer, you are halfway there, but if you don’t have one, a cheap one will set you back less than $200 and maybe even less if you pick one up used.

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Art of 3D printer in the middle of printing a Hackaday Jolly Wrencher logo

3D Printering: Adaptive Bed Leveling

Have you ever read about something and thought, “Gee whiz! Why did I never think about that?” That was my reaction to reading about a feature commonly associated with Klipper called adaptive bed leveling or adaptive mesh leveling. Too bad I don’t typically use Klipper, but it all worked out, and I’ll show you how it might work for you.

What Is It?

Time to tram your bed!

Once a luxury, most 3D printers now come with some kind of bed level sensor. The idea is that the printer can probe the bed to determine the shape of the build plate and then adjust the build plate accordingly. So if a particular spot on the bed is 0.5 mm too high, the nozzle can rise 0.5 mm when it is in that area. There are several techniques Marlin firmware uses, including what I usually use: UBL. Some people scan the bed once and hope it won’t change much. Others will do a time-consuming scan before each print.

However, adaptive bed leveling is a bit different. The idea is that the printer only probes the area where the part is going to print. If your print bed is 235 mm x 235 mm but your part is 50 mm square, you could just probe the points under the 50 mm square.

This does several things. For a given number of points, there is less motion, so it should be faster. Also, for the same number of points, you will have a much denser mesh and, thus, a better idea of what the bed is at any given point. You could even reduce the number of points based on the size of the part you are printing.

When you think about it, it is a dead simple idea. What’s not to love? For most print jobs, you’ll have less work for the printer, faster prints, and a denser mesh. But how do you do it?

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Adding Texture To 3D Prints

[3DJake] likes putting textures on 3D prints using things like patterned build plates and fuzzy skin. However, both of those techniques have limitations. The build plate only lets you texture the bottom, and the fuzzy skin texture isn’t easy to control. So he shows how to use Blender to create specific textures to produce things like wood-like or leather-like surfaces, for example. You can see how it works in the video below.

As [Jake] points out, you might be able to use other artistic programs to do this, but the kind of things we use like FreeCAD of Fusion360 aren’t going to cut it.

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Studying The Finer Points Of 3D Printed Gears

[How to Mechatronics] on YouTube endeavored to create a comprehensive guide comparing the various factors that affect the performance of 3D printed gears. Given the numerous variables involved, this is a challenging task, but it aims to shed light on the differences. The guide focuses on three types of gears: the spur gear with straight teeth parallel to the gear axis, the helical gear with teeth at an angle, and the herringbone gear, which combines two helical gear designs. Furthermore, the guide delves into how printing factors such as infill density impact strength, and it tests various materials, including PLA, carbon fiber PLA, ABS, PETG, ASA, and nylon, to determine the best options.

The spur gear is highly efficient due to the minimal contact path when the gears are engaged. However, the sudden contact mechanism, as the teeth engage, creates a high impulse load, which can negatively affect durability and increase noise. On the other hand, helical gears have a more gradual engagement, resulting in reduced noise and smoother operation. This leads to an increased load-carrying capacity, thus improving durability and lifespan.

It’s worth noting that multiple teeth are involved in power transmission, with the gradual engagement and disengagement of the tooth being spread out over more teeth than the spur design. The downside is that there is a significant sideways force due to the inclined angle of the teeth, which must be considered in the enclosing structure and may require an additional bearing surface to handle it. Herringbone gears solve this problem by using two helical gears thrusting in opposite directions, cancelling out the force.

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Building An 8-Color Automated Filament Changer

Multi-filament printing can really open up possibilities for your prints, even more so the more filaments you have. Enter the 8-Track from [Armored_Turtle], which will swap between 8 filaments for you!

The system is modular, with each spool of filament installed in a drybox with its own filament feeder .The dryboxes connect to the 8-Track changer via pogo pins for communication and power. While [Armored_Turtle] is currently using the device on a Voron printer, he’s designed it so that it can be easily modified to suit other printers. As it’s modular, it’s also not locked into running 8 filaments. Redesigning it to use more or less is easy enough thanks to its modular design.

The design hasn’t been publicly released yet, but [Armored_Turtle] states they hope to put it on Github when it’s ready. It’s early days, but we love the chunky design of those actively-heated drybox filament cassettes. They’re a great step up from just keeping filament hanging on a rod, and they ought to improve print performance in addition to enabling multi-filament switching.

We’ve seen some other neat work in this space before, too. Video after the break.

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Roboticized 3D Printer Has Been Developing Shock Absorbing Structures For Years

Imagine you want to iterate on a shock-absorbing structure design in plastic. You might design something in CAD, print it, then test it on a rig. You’ll then note down your measurements, and repeat the process again. But what if a robot could do all that instead, and do it for years on end? That’s precisely what’s been going on at Boston University.

Inside the College of Engineering, a robotic system has been working to optimize a shape to better absorb energy. The system first 3D prints a shape, and stores a record of its shape and size. The shape is then crushed with a small press while the system measures how much energy it took to compress. The crushed object is then discarded, and the robot iterates a new design and starts again.

The experiment has been going on for three years continuously at this point. The MAMA BEAR robot has tested over 25,000 3D prints, which now fill dozens of boxes. It’s not frivolous, either. According to engineer Keith Brown, the former record for a energy-absorbing structure was 71% efficiency. The robot developed a structure with 75% efficiency in January 2023, according to his research paper.

Who needs humans when the robots are doing the science on their own? Video after the break.

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