Thrift Store CD Rack Turns Into Small Parts Storage Playground

March 17, 2024 by Dan Maloney 15 Comments

What in the world could an accessory for an obsolete audio medium possibly have to do with keeping all your unruly bits and pieces in order? First of all, we’re not sure the CD is quite dead yet; we’ve got about a thousand of them packed away somewhere, and we’re pretty sure they’ll be back in style again one of these days. Until then, though, the lowly CD rack might be just what you need to get your shop under control.

As [Chris Borge] relates the story, he stumbled over this CD rack at a thrift sale and quickly realized its potential. All it took was some quick design work and a bit of 3D printing. Okay, a lot of 3D printing, including some large, flat expanses for the drawer bottoms, which can be a problem to print reliably. His solution was simple but clever: pause the print and insert a piece of stiff card stock to act as the drawer bottom before continuing to print the sides. This worked well but presented an adhesion problem later when he tried to print some drawer dividers, so those were printed as a separate job and inserted later.

Sadly, [Chris] notes that the CD format is not quite Gridfinity compatible, but that’s not a deal breaker. He also doesn’t provide any build files, but none are really necessary. Once you’ve got the basic footprint, what you do with your drawers is largely dependent on what you’ve got to store. The video below has a lot of ideas for what’s possible, but honestly, we’re looking at all those little parts assortment kits from Bojack and Hilitchi piled up in a drawer and just dreaming about the possibilities here. Add a voice-activated, LED inventory locator, and you’d really have something. Off to the thrift store!

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Design Tips To Hide Layer Lines In 3D Printed Parts

March 4, 2024 by Donald Papp 31 Comments

[Slant 3D] knows a lot about optimizing 3D prints so that they can be cranked out reliably with minimal need for post-processing, and in this short video he uses a cube as a simple example of how a few design changes can not only optimize for production, but can even hide layer lines pretty effectively.

Just to be perfectly clear, layer lines cannot be eliminated entirely without some kind of post-processing. But [Slant 3D]’s tips sure goes a long way toward making a part lose that obvious 3D-printed “look”. They also dovetail nicely with advice on how to optimize cranking out high numbers of parts in a print farm.

Adding texture to the outer layer is especially effective when combined with non-traditional part orientations.

One simple way to avoid visible layer lines is to put some kind of texture onto the part. This can be modeled into the part’s surface, or the slicer software can be used to modify the exterior of the print to add a texture such as a geometric pattern or by applying a fuzzy skin modifier.

Printing a texture onto the exterior is great, but the outcome can be even further improved by also printing the object in a non-traditional orientation.

Using a cube as an example, printing the cube on a corner has the advantage of putting the layer lines in a different orientation as well as minimizing the contact area on the print bed. This applies the texture across more of the part, and looks less obviously 3D printed in the process. Minimizing bed adhesion also makes parts much easier to remove, which has obvious benefits for production. [Slant 3D] points out that performing these operations on a 3D-printed part is essentially free.

A few other optimizations for production involve rounding sharp corners to optimize tool travel paths, and putting a slight chamfer on the bottom of parts to avoid any elephant foot distortion (Elephant’s foot can be compensated for, but simply putting a slight chamfer on a part is a design change that helps avoid accounting for machine-to-machine variance.)

Even if one has no need to optimize for high production volume, the tips on hiding layer lines with design changes is great advice. Watch it all in action in the short video, embedded below.

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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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