Long-Awaited SLS4All 3D Printer Now Shipping

June 13, 2024 by Dave Rowntree 36 Comments

We touched on the open source SLS4All DIY SLS 3D printer a year or two ago when the project was in the early stages. Finally, version one is complete, with a parts kit ready to ship and all design data ready for download if a DIY build or derivative is your style. As some already mentioned, this is not going to be cheap: with the full parts kit running at an eye-watering $7K before tax. But it’s possible to build or source almost all of it a bit at a time for those on a budget.

Try printing THIS benchy on an FDM machine!

It’s important to note that to access the detailed information, you’ll need to create an account, which is a bit inconvenient for an open source design. However, all the essential components seem to be available, so it’s forgivable. In terms of electronics, there are two custom PCBs: the GATE1 (GAlvo and Temperature Control) and the ZERO1 (Zero-crossing dimming) controller. Other than that, all the electronics seem to be standard off-the-shelf components. Both of these PCBs are designed using EasyEDA.

Unfortunately we couldn’t find access to the PCB Gerbers, nor does there appear to be a link to their respective EasyEDA projects, just the reference schematics. This is a bit of a drawback, but it’s something that could easily be reproduced with enough motivation. Control is courtesy of a Radxa Rock Pi, as there were ‘problems’ with a Raspberry Pi. This is paired with a 7-inch touchscreen to complete the UI. This is running a highly modified version of the Klipper together with their own control software, which is still undergoing testing before release.

The laser head is built around a 10 W 450 nm laser module from China and a high-end galvanometer set. Two 200 W halogen tube heaters heat the print bed, and 200 W silicone heating pads heat both the powder bed and the print bed.

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The Dyke Delta: A DIY Flying Wing Fits Four

June 4, 2024 by Elliot Williams 24 Comments

The world of experimental self-built aircraft is full of oddities, but perhaps the most eye-catching of all is the JD-2 “Dyke Delta” designed and built by [John Dyke] in the 1960s. Built to copy some of the 1950’s era innovations in delta-style jet aircraft, the plane is essentially a flying wing that seats four.

And it’s not just all good looks: people who have flown them say they’re very gentle, they get exceptional gas mileage, and the light wing-loading means that they can land at a mellow 55 miles per hour (88 kph). And did we mention the wings fold up so you can store it in your garage?

Want to build your own? [John] still sells the plans. But don’t jump into this without testing the water first — the frame is entirely hand-welded and he estimates it takes between 4,000 and 5,000 hours to build. It’s a labor of love. Still, the design is time-tested, and over 50 of the planes have been built from the blueprints. Just be sure to adhere to the specs carefully!

It’s really fun to see how far people can push aerodynamics, and how innovative the experimental airplane scene really is. The JD-2 was (and probably still is!) certainly ahead of its time, and if we all end up in flying wings in the future, maybe this plane won’t look so oddball after all.

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Homebrew Computer From The Ground Up

May 26, 2024 by Bryan Cockfield 12 Comments

Building a retro computer of some sort is a rite of passage for many of us, with some building replicas or restorations of old Commodores, Ataris, and other machines from decades past. Others go even further back, to the time of the Intel 8008 or earlier, and a dedicated few will build something completely novel. This project from [3DSage] falls squarely in the latter category, with his completely DIY computer built component by component from scratch, including the machine code needed to run it.

[3DSage] starts with the backbone of every computer: the clock. He first demonstrates how a pair of NOT gates with a set of capacitors can be used as a rudimentary clock pulse, then builds a more refined version with a 555 timer and potentiometer for adjustable rates. Then, it’s on to creating a binary counter, which is a fundamental part of the memory system for this small computer, and finally, allows this circuitry to behave like a normal computer. Using a set of switches to store values in memory and stepping through them with the clock, the computer can be programmed to do plenty of tasks just like a modern microcontroller.

[3DSage] built this project a few years ago and has used it for real-world applications such as controlling servos, LED arrays, playing music, and other tasks. Although he has to program it using his own machine code by hand, it’s a usable computer in many ways. If you want to eschew modernity and build a retro computer in the style of the 1960s, though, this piece goes through what it would have been like to build a similar system in the era when these computers were more common. If you have a switch fetish, you might like to see how real computers worked back then, too.

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A Vernier Take On A 3D Printer Extruder Indicator

May 3, 2024 by Donald Papp 6 Comments

A common way to visualize that a 3D printer’s extruder motor — which feeds the filament into the hot end — is moving is to attach a small indicator to the exposed end of the motor’s shaft. As the shaft turns, so does the attached indicator.

Small movements of the motor are therefore turned into larger movements of something else. So far, so simple. But what about visualizing very small extrusions, such as those tiny ones made during ironing?

[Jack]’s solution is a Vernier indicator for the extruder. Even the smallest movements of the extruder motor’s shaft are made clearly visible by such a device, as shown in the header image above. Vernier scales are more commonly found on measurement tools, and the concept is somewhat loosely borrowed here.

The usual way these lightweight indicators are attached is with a small magnet, and you can read all about them and see examples here.

This new design is basically the same, it simply has a background in a contrasting color added into the mix. [Jack]’s design is intended for the Bambu A1 printer, but the idea can be easily adapted. Give it a look if you find yourself yearning for a bit more visibility in your extruder movements.

DIY Quad-Motor Go-Kart Is A Thrilling Ride

April 18, 2024 by Donald Papp 29 Comments

[Peter Holderith] set out some time ago to build an electric go-kart. That by itself is not terribly unusual, but where his project diverts from the usual is in the fact that each of the four wheels has an integrated hub motor.

It might not look it, but each wheel has an integrated hub motor.

This kart project is a bit of a work in progress, with [Peter] previously building (then scrapping) a failed attempt at a cheap suspension system. But it’s completely operational with all four wheels able to deliver a monstrous amount of power despite being limited by the power supply (a battery pack salvaged from an Audi Q5 Hybrid).

The kart might not look it, but it weighs 177 pounds (80 kg) with the battery and motors accounting for nearly half of that. What is is like to drive? “Nothing short of thrilling,” says [Peter]. It’s got no suspension and is pretty bare bones, not to mention limited in power by the battery, but [Peter] finds it a satisfying drive that nevertheless delivers car-like cues in the driving experience. The build isn’t done, and [Peter] plans to see if more power is available by switching battery chemistries rather than add more battery weight.

Building and driving electric vehicles can be remarkably satisfying, and it’s an area in which hobbyists can meaningfully innovate. Self-balancing one-wheeled vehicles for example look like a ton of fun. Heck, researchers have discovered that even rats seem to enjoy driving just for the fun of it.

TOPS, The DIY Robot Dog, Has Great Moves

March 15, 2024 by Donald Papp 6 Comments

We love [Aaed Musa]’s TOPS (Traverser of Planar Surfaces) which is a robot dog with custom-made actuators. The DIY is very strong with this project, and the 3D-printed parts alone took a whopping three weeks to print!

There’s additional detail on the electronics and design of TOPS in the build log of the project’s Hackaday.io page, so check it out because there are all sorts of nice design details, like the feet being cast with a silicone outer layer for better traction. We’ve previously covered [Aaed]’s DIY robotic actuator design which we’re delighted to see is put to excellent use in the finished robot.

Of course, a robot’s hardware and physical design is only part of the battle. In fact, [Aaed] says the software side of things was probably the biggest overall challenge. It takes a lot of work to make walking happen, and the process has in fact been a huge learning experience. [Aaed] already has plenty of ideas for a potential TOPS V2.

[Aaed]’s website has video tours of all stages of design and construction of TOPS, and there’s a GitHub repository for all the design details. To see it all in action, check out the short video rounding up the finished robot, embedded here just under the page break.

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A vanadium based flow battery made with 3D printed parts

A Vanadium Redox Flow Battery You Can Build

March 9, 2024 by Dave Rowntree 36 Comments

Vanadium flow batteries are an interesting project, with the materials easily obtainable by the DIY hacker. To that effect [Cayrex2] over on YouTube presents their take on a small, self-contained flow battery created with off the shelf parts and a few 3D prints. The video (embedded below) is part 5 of the series, detailing the final construction, charging and discharging processes. The first four parts of the series are part 1, part 2, part 3, and part 4.

The concept of a flow battery is this: rather than storing energy as a chemical change on the electrodes of a cell or in some localised chemical change in an electrolyte layer, flow batteries store energy due to the chemical change of a pair of electrolytes. These are held externally to the cell and connected with a pair of pumps. The capacity of a flow battery depends not upon the electrodes but instead the volume and concentration of the electrolyte, which means, for stationary installations, to increase storage, you need a bigger pair of tanks. There are even 4 MWh containerised flow batteries installed in various locations where the storage of renewable-derived energy needs a buffer to smooth out the power flow. The neat thing about vanadium flow batteries is centred around the versatility of vanadium itself. It can exist in four stable oxidation states so that a flow battery can utilise it for both sides of the reaction cell.