We’ll go out on a limb here and say that a large portion of Hackaday readers are also boat-builders. That’s a bold statement, but as the term applies to anyone who has built a boat, we’d argue that it encompasses anyone who’s run off a Benchy, the popular 3D printer test model. Among all you newfound mariners, certainly a significant number must have looked at their Benchy and wondered what a full-sized one would be like. Those daydreams of being captain of your ship may not have been realized, but [Dr. D-Flo] has made them a reality for himself with what he claims is the world’s largest Benchy. It floats, and carries him down the waterways of Tennessee in style!
The video below is long but has all the details. The three sections of the boat were printed in PETG on a printer with a one cubic meter build volume, and a few liberties had to be taken with the design to ensure it can be used as a real boat. The infill gaps are filled with expanding foam to provide extra buoyancy, and an aluminium plate is attached to the bottom for strength. The keel meanwhile is a 3D printed sectional mold filled with concrete. The cabin is printed in PETG again, and with the addition of controls and a solar powered trolling motor, the vessel is ready to go. Let’s face it, we all want a try!
Benchy is that cute little boat that everyone uses to calibrate their 3D printer. [Emily The Engineer] asked the obvious question—why isn’t it a real working boat? Then she followed through on the execution. Bravo, [Emily]. Bravo.
The full concept is straightforward, but that doesn’t make it any less fun. [Emily] starts by trying to get small Benchys to float, and then steadily steps up the size, solving problems along the way. By the end of it, the big Benchy is printed out of lots of smaller sections that were then assembled into a larger whole. This was achieved with glue and simply using a soldering iron to melt parts together. It’s a common technique used to build giant parts on smaller 3D printers, and it works pretty well.
The basic hull did okay at first, save for some stability problems. Amazingly, though, it was remarkably well sealed against water ingress. It then got a trolling motor, survived a capsizing, and eventually took to the open water with the aid of some additional floatation.
Making something enjoyable often requires a clever trick. It could be a way to cut something funny or abuse some peripheral in a way it was never designed for. Especially good tricks have a funny way of coming up again and again. [DERAILED3D] put a 3d printed benchy in a bottle with one of the best tricks 3d printing has.
The trick is stopping the print part way through and tweaking it. You can add manual supports or throw in some PTFE beads to make a generator. The benchy isn’t the print being paused; the bottle is. The benchy is a standard print, and the bottle is clear resin. Once halfway through, they paused the print, and the benchy was left suspended in the bottle with a bit of wire. Of course, [DERAILED3D] moved quickly as they risked a layer line forming on the delicate resin after a minute or two of pausing. The difficulty and mess of tweaking a gooey half-finished resin print is likely why we haven’t seen many attempts at playing with the trick, but we look forward to more clever hacks as it gets easier.
The real magic is in the post-processing of the bottle to make it look as much like glass as possible. It’s a clever modern twist on the old ship in the bottle that we love. Video after the break.
Truth be told, we generally find speed sports to be a little boring. Whether it’s cars going around in circles for hours on end or swimmers competing to be a few milliseconds faster than everyone else, we just don’t feel the need for speed. Unless, of course, you’re talking about speedy 3D printers like “The 100”, which claims to produce high-quality prints in a tenth the time of an ordinary printer. In that case, you’ve got our full attention.
What makes [Matt the Printing Nerd]’s high-speed printer interesting isn’t the fact that it can do a “Speedboat Run” — printing a standard Benchy model — in less than six minutes. Plenty of printers can do the same thing much, much faster. The impressive part is that The 100 does it with a 3D-printed frame. In fact, most of the printer’s parts are 3d printed, a significant departure from most speed printer builds, which generally shy away from printed structural elements. [Matt]’s design also aims to keep the center of gravity of all the printer’s components within a very small area, which helps manage frame vibrations that limit print quality. The result is that the CoreXY gantry is capable of a speed of 400 mm/s and an eye-popping 100,000 mm/s² acceleration. What also sets [Matt]’s printer apart is that The 100 is designed to be a daily driver. It has a generous 165 mm x 165 mm print bed, which is far more useful than a bed that’s barely bigger than a standard Benchy.
The video below has much more details on the open-source build, plus some nice footage of some speed runs. The quality of the prints, even done at speed, is pretty impressive. Perhaps there is a point to speed sports after all.
Remember that time back in 2021 when a huge container ship blocked the Suez Canal and disrupted world shipping for a week? Well, something a little like that is playing out again, this time in the Chesapeake Bay outside of the Port of Baltimore, where the MV Ever Forward ran aground over a week ago as it was headed out to sea. Luckily, the mammoth container ship isn’t in quite as narrow a space as her canal-occluding sister ship Ever Given was last year, so traffic isn’t nearly as impacted. But the recovery operation is causing a stir, and refloating a ship that was drawing 13 meters when it strayed from the shipping channel into a muddy-bottomed area that’s only about 6 meters deep is going to be quite a feat of marine engineering. Merchant Marine YouTuber Chief MAKOi has a good rundown of what’s going on, and what will be required to get the ship moving again.
With the pace of deep-space exploration increasing dramatically of late, and with a full slate of missions planned for the future, it was good news to hear that NASA added another antenna to its Deep Space Network. The huge dish antenna, dubbed DSS-53, is the fourteenth dish in the DSN network, which spans three sites: Goldstone in California; outside of Canberra in Australia; and in Madrid, where the new dish was installed. The 34-meter dish will add 8% more capacity to the network; that may not sound like much, but with the DSN currently supporting 40 missions and with close to that number of missions planned, every little bit counts. We find the DSN fascinating, enough so that we did an article on the system a few years ago. We also love the insider’s scoop on DSN operations that @Richard Stephenson, one of the Canberra operators, provides.
Does anybody know what’s up with Benchy? We got a tip the other day that the trusty benchmarking tugboat model has gone missing from several sites. It sure looks like Sketchfab and Thingiverse have deleted their Benchy files, while other sites still seem to allow access. We poked around a bit but couldn’t get a clear picture of what’s going on, if anything. If anyone has information, let us know in the comments. We sure hope this isn’t some kind of intellectual property thing, where you’re going to have to cough up money to print a Benchy.
Speaking of IP protections, if you’ve ever wondered how far a company will go to enforce its position, look no further than Andrew Zonenberg’s “teardown” of an anti-counterfeiting label that Hewlett Packard uses on their ink cartridges. There’s a dizzying array of technologies embedded inside what appears to be a simple label. In addition to the standard stuff, like the little cuts that make it difficult to peel a tag off one item and place it on another — commonly used to thwart “price swapping” retail thefts — there’s an almost holographic area of the label. Zooming in with a microscope, the color-shifting image appears to be made from tiny hexagonal cells that almost look like the pixels in an e-ink display. Zooming in even further, the pixels offer an even bigger (smaller) surprise. Take a look, and marvel at the effort involved in making sure you pay top dollar for printer ink.
And finally, we got a tip a couple of weeks ago on a video about jerry cans. If that sounds boring, stop reading right now — this one won’t reach you. But if you’re even marginally interested in engineering design and military history, make sure you watch this video. What is now known to the US military as “Can, Gasoline, Military 5-Gallon (S/S by MIL-C-53109)” and colloquially known as the NATO jerry can, started life as the Wehrmacht-Einheitskanister, a 20-liter jug whose design addresses a long list of specifications, from the amount of liquid it could contain to how the cans would be carried. The original could serve as a master class in good design, and some of the jugs that were built in the 1940s are still in service and actively sought by collectors of militaria. Cheap knockoffs are out there, of course, but after watching this video, we’ve developed a taste for jerry cans that only the original will sate.
The idea behind the SpeedBoatRace is how quickly you can print a Benchy — the little boat that is used as a test print for a 3d printer. Speeding up a print is quite tricky as it means moving the head quicker and giving layers less time to deposit and a whole other host of problems. So [Roetz] took a page out of a CPU designer’s playbook, and rather than increasing the latency, he raised the throughput. The original plan was for 20 hot ends, but due to cooling issues, that had to be reduced to 18. Perhaps even more impressive than the scale of the machine is that the only off-the-shelf parts on it are the fans for cooling. Everything else is printed or machined by [Roetz] himself. The whole run was completed in less than an hour, which technically gives him a sub 3.6 minute time per benchy, even accounting for a few that failed.
As anyone who has used a 3D printer before knows, what comes off the bed of your regular FSD printer is by no means a mirror finish. There are layers in the print simply by the nature of the technology itself, and the transitions between layers will never be smooth. In addition, printers can use different technology for depositing layers, making for thinner layers (SLA, for example). With those challenges in mind, [AlphaPhoenix] set out to create an authentic mirror finish on his 3D prints. (Video, embedded below.)
As the intro hints, mirrors need very flat/smooth surfaces to reflect light. To smooth his prints, [AlphaPhoenix] first did a light sanding pass and then applied very thick two-part epoxy, allowing surface tension to do the smoothing work for him. Once dried, silver was deposited onto the pieces via a few different sprays. First, a wetting agent is applied, which prevents subsequent solutions from beading up. Next, he sprays the two precursors, and they react together to deposit elemental silver onto the object’s surface. [AlphaPhoenix] asserts that he isn’t a chemist and then explains some of the many chemical reactions behind the process and theorizes why the solutions break down a while after being mixed.
He had an excellent first batch, and then subsequent batches came out splotchy and decided un-mirror-like. As we mentioned earlier, the first step was a wetting agent, which tended to react with the epoxy that He applied. Then, using a grid search with four variables, [AlphaPhoenix] trudged through the different configurations, landing on critical takeaways. For example, the curing time for the epoxy was essential and the ratio between the two precursor solutions.
