Texture Trick For 3D Prints From The Stone Age

August 21, 2018 by Tom Nardi 14 Comments

Arguably one of the most difficult aspects of 3D printing is trying to make the finished product look like it wasn’t 3D printed. It can take a lot of time and work to cover up the telltale layer lines (or striations, if you want to get fancy), especially if your 3D printer isn’t perfectly calibrated. While there aren’t many shortcuts to achieve a glass-like finish on 3D printed parts, if your end goal is to make something that looks like stone, [Wekster] has a tip for you.

He demonstrates the technique by building a gorgeous recreation of the main gate from Jurassic Park. The process gives the relatively smooth plastic the gnarled look of rough-hewn stone with very little in the way of manual work. While it’s true there’s no overabundance of projects this stone-look finish will work for, it’s definitely something we’ll be filing away mentally.

So what’s the secret? [Wekster] first coats the 3D printed parts with common wood filler, the sort of stuff available at any hardware store. He then wraps them in clear plastic wrap, allowing the wrap to bunch up rather than trying to pull it taught. For extra detail, he digs into the plastic wrap here and there to create what will appear to be gaps and cracks on the finished piece. The wood filler is then left to dry; a process which normally only takes a few minutes, but now will take considerably longer as the plastic wrap will be keeping the air from it.

Once its hardened and unwrapped, [Wekster] sprays it with a base coat of color, and follows up with a few washings with watered down black and gray paints. This technique is well known to anyone who’s done miniature or model painting; serving to highlight the surface texture and give the finish more depth. With this method, anything that resembles a layer line in the print is long gone, and the surface looks so complex and detailed that at first glance few would believe it’s plastic.

[Wekster] also used wood filler during the finishing process for his Fallout 4 “Thirst Zapper” replica. In the past we’ve shown how you can smooth out 3D printed parts with epoxy and taken a very scientific look at using UV resin as a conformal coating, but maybe it’s time we give wood filler a shot.

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Leather Working With A 3D Printer

August 14, 2018 by Al Williams 22 Comments

No, you can’t print in leather — at least not yet. But [Make Everything] has a tutorial about how to produce a custom leather embossing jig with a 3D printer. From a 3D printing point of view, this isn’t very hard to do and you might want to skip over the first six minutes of the video if you’ve done 3D printing before.

The real action is when he has the 3D print completed. He glues the stamp down to some wood and then fits the assembly to a vise that he’ll use as a press. After wetting the leather, the wood and 3D printed assembly sandwiches the piece and the vise applies pressure for ten minutes. He did make the leather a bit oversized to make alignment more forgiving. After the embossing is complete, he trims it out.

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Modern PC Crammed Into An Original Xbox

August 13, 2018 by Tom Nardi 19 Comments

When the original Microsoft Xbox was released in 2001, one of the most notable features of its design was that it used a number of off-the-shelf computer components. Inside contemporary offerings from Nintendo and Sony you’ll see almost nothing but proprietary components, whereas cracking open the Xbox reveals an IDE hard drive, a customized PC DVD-ROM drive, and an Intel Pentium III CPU. Depending on which team you were on, the Xbox’s close relation to PC hardware of the day was either a point of honor or ridicule in the early 2000’s console wars; but regardless of politics, it ended up being instrumental in all of the hacks and mods the console got over its lifetime.

In that light, [P8ntBal1551] managing to jam a modern computer into the shell of an Xbox is like having the last laugh in this nearly two-decade-old debate. Wanting to build an HTPC that wouldn’t look out of place in his entertainment center, he figured the Xbox would make a suitable home for his Intel 4460 powered build. Not to say it was easy: getting all of the hardware and associated wiring inside the case took a bit of cheating, but the end result looks good enough that we’ll give him a pass.

The key to this project is the 3D printed structure inside the Xbox’s case that holds everything together. Painstakingly designed to align all of his components and cooling fans, it took over 58 hours to print just the base plate alone on his CR-10.

Even with all of his primary components installed, [P8ntBal1551] still had to wrestle with an absolute rat’s nest of wiring. He couldn’t find smaller versions of a number of the cables he needed, so he had to resort to some creative wire management to get everything packed in there. In the end, there was simply too much gear for the Xbox’s case to legitimately fit, so he ended up printing a spacer to fit between the bottom and top halves. Though in the end even this worked out in his favor, as it gave him a place to mount the integrated FLIRC IR receiver without having to cut a hole in the original front panel. The end product looks close enough to stock to be almost unnoticeable to the casual observer.

Its been a while since we’ve seen a hack for Microsoft’s original black and green monster, most of the Xbox projects we see are in relation to its significantly more popular successor. It’s always nice to see people keeping the classics alive in their own way.

[via /r/pcmasterrace]

3D Printing, Cybersecurity, And Audio Fingerprinting

July 24, 2018 by Al Williams 18 Comments

We all understand the risk of someone taking over our computers or phones for nefarious purposes. But remote access to printers and fax machines was something most people took a little less seriously. After all, you might get some obscene printouts or someone wasting some paper, but in general, those are not big deals. Some researchers however have lately been pondering what might happen should someone break into your 3D printer. Of course, you could bring a printer down to deny service, or cause things to malfunction — maybe even in ways that could be dangerous if the printer didn’t have sufficient safety features. But these researchers are more crafty. They are studying how you know what you’ve printed hasn’t been subtly sabotaged. They also think they have an answer.

If you are printing another Benchy at home this probably isn’t a real concern. However, according to the paper, 3D printing now accounts for over $6 billion of revenue with 33.8% of all parts having some function. This includes a recent FAA approval for a 3D-printed fuel nozzle for a jet engine. So indulge us in a little science fiction. You are about to fly your drone to take video of an important social function. You are worried about one of your props, so you 3D print a new one. Too bad your competitor has hacked your computer with a phishing e-mail and modified your STL files so that the new prop will have built-in weak spots internally. The prop will look fine and you’ll be able to install it. But it is going to fail right when you are taking those critical shots.

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Failed 3D Print Saved With Manual Coding

July 20, 2018 by Al Williams 20 Comments

Toast falls face down. Your car always breaks after the warranty period. A 3D print only fails after it is has been printing for 12 hours. Those things might not always be true, but they are true often enough. Another pessimistic adage is “no good deed goes unpunished.” [Shippey123] did a good deed. He agreed to make a 3D printed mask for his friend to give as a gift. It was his first print he attempted for someone else after about four months’ experience printing at all. After 20 hours of printing, he noticed the head was moving around in the air doing nothing — a feeling most of us are all too familiar with. But he decided not to give up, but to recover the print.

Luckily, he’s a CNC machinist and is perfectly capable of reading G-code. The first thing he did was to shut everything down and clear the head. Then he rehomed the printer and used the head to determine what layer the printer had been working on when it failed. He did that by moving over a hidden part of the print and lowering the head by 100 microns. Then he’d move the head a few millimeters in the X direction to see if the head was touching.

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A Farewell To Printrbot

July 19, 2018 by Tom Nardi 71 Comments

It’s with a heavy heart that we must report Printrbot has announced they are ceasing operations. Founded in 2011 after a wildly successful Kickstarter campaign, the company set out to make 3D printing cheaper and easier. Their first printer was an amalgamation of printed parts and wood that at the time offered an incredible deal; when the Makerbot CupCake was selling for $750 and took 20+ hours to assemble, the Printrbot kit would only run you $500 and could be built in under an hour.

Printrbot got their foot in the door early, but the competition wasn’t far behind. The dream of Star Trek style replicators fueled massive investment, and for a while it seemed like everyone was getting into the 3D printing game. Kit built machines gave way to turn-key printers, and the prices starting coming down. Printrbot’s products evolved as well, dropping wood in favor of folded steel and pioneering impressive features like automatic bed leveling. In 2014 they released the Printbot Simple Metal, which ultimately became their flagship product and in many ways represents the high water mark for the company.

Eventually, overseas manufacturers saw an opportunity and started flooding the market with 3D printers that were cheaper than what many would have believed possible only a few years earlier. Today you can go online and buy a perfectly serviceable starter printer for under $200, even less if you’re still willing to build it yourself. For an American company like Printrbot, competing at this price point was simply an impossibility.

Rather than give up, Brook decided to take things in a different direction. If he couldn’t compete with imported machines on price, he would start building high end printers. A new version of the Simple Metal was introduced in 2016 with premium features such as linear rails and cloud-based slicing, complete with a premium price. From that point on, most new Printrbot products would release at over $1,000; putting them more in line with “prosumer” machines from companies like Ultimaker. For hacker types who got their first taste of 3D printing thanks to a cheap wooden Printrbot kit, this was something of a bittersweet moment.

At the same time, Brook’s natural hacker spirit and love of the open source community lead to a number of interesting side projects that never quite got off the ground. Most recently, he’d been putting the finishing touches on the Printrbelt, a 3D printer with a conveyor belt in place of a traditional bed. Such a machine could finally bridge the gap between desktop 3D printing and true small scale production capability.

When we saw Brook at the East Coast RepRap Festival, he brought along a new machine that the more cynical observer might have taken as foreshadowing. The Printrbot Easy was going to be a modified and rebranded FlashForge Finder, a final acknowledgement that the only way to compete with the Chinese manufactured 3D printers was to sell one of your own.

It’s always sad to see a tech company go under, but seeing the end of Printrbot is especially hard. Built in America with locally sourced components and with a commitment to keeping their machines open source, there was a lot to love about the plucky little 3D printer company from Lincoln, California. Printrbot was the quintessential hacker success story, and we’re proud to say we’ve been in their corner from the start. Here’s to wishing Brook Drumm and the entire Printrbot team success in their future endeavors; we’ll be keeping an eye out.

ERRF 18: The Start Of Something Great

July 18, 2018 by Tom Nardi 7 Comments

For years, the undisputed king of desktop 3D printing conferences has been the Midwest RepRap Festival (MRRF). Hosted in the tropical paradise that is Goshen, Indiana, MRRF has been running largely unopposed for the top spot since its inception. There are other conferences focused on the industrial and professional end of the 3D printing spectrum, and of course you’d find a Prusa or two popping up at more or less any hacker con; but MRRF is focused on exploring what the individual is capable of once they can manifest physical objects from molten plastic.

But on June 23rd, 2018, MRRF finally got some proper competition. As the name might indicate, the East Coast RepRap Festival (ERRF) is an event very much inspired by its Hoosier State predecessor. Held in Bel Air, Maryland, hackers on the right side of the United States for the first time had the opportunity to attended a true 3D printing festival without having to get on a plane. Not to say it was a neighborhood block party; people from all over the country, and indeed the globe, descended on the APG Federal Credit Union Arena for the two-day celebration of everything plastic.

This inaugural ERRF was, to put it mildly, a massive success. A couple of Hackaday Field Agents were in attendance, and we definitely came away impressed with the event considering it was the first attempt. We saw evidence that the RepRap dream of printable printers is still going strong, a gaggle of new printers and products that will be prying at your wallet this year, and an American-made hotend that challenges traditional wisdom. Of course we also saw a huge number of 3D printing fanatics who were eager to show off their latest creations.

We have no doubt that ERRF will return again next year, but until then, you’ll have to settle for the following collection of selected highlights from this year’s show.

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