freecad

39 Articles

FreeCAD Is Near 1.0

September 21, 2024 by 46 Comments

The open-source parametric 3D modelling software, FreeCAD, is out in a release candidate for version 1.0.  If you’ve tried FreeCAD before and found a few showstoppers, it might be a good time for you to test it out again because the two biggest of them have been solved in this latest version.

First, version 1.0 finally implements a solution to the “topological naming problem”. Imagine you want to put a hole into a surface. The program needs to know on which surface to put the hole, and so it refers to this surface by name / number. Now imagine you subdivide the surface, and both subsections get new names. Where does your hole go now?  If you want to dig into the issue, the inimitable [MangoJelly] has a great video about the topo naming problem. Practically, there were workarounds, like only adding chamfers after the main design has stabilized, but frankly it was a hassle to remember all of the tricks. This is a huge fix.

The second big fix concerns assemblies.  Older versions of FreeCAD were great for making single parts, but combining them all together inside the CAD program was always janky.  Version 1.0 combines the previous two patchwork assembly workbenches into one, and it’s altogether more pleasant to use. The constraints of how two parts move when held together with an axle just works now, and this is a big deal for multi-part models.

If you’re coming from any other parametric CAD program, most of FreeCAD will seem familiar to you, but there will also be workflow differences that will take some getting used to. In trade, what do you get? Scriptability in Python, real open source software, and all of the bells and whistles for free. Now that its two biggest pain points have been addressed,  FreeCAD has become a lot easier to love. We’re looking forward to some good V1.0 tutorials in the future, and we’ll keep you posted when we find them.

An L-shaped orange mounting structure with two white reservoirs on top, a set of pumps on the outer bottom edges, and a membrane cell bolted together in the center. The parts are connected by a series of transparent tubes.

Open Source Residential Energy Storage

August 15, 2024 by 20 Comments

Battery news typically covers the latest, greatest laboratory or industry breakthroughs to push modern devices further and faster. Could you build your own flow battery stationary storage for home-built solar and wind rigs though?

Based on the concept of appropriate technology, the system from the Flow Battery Research Collective will be easy to construct, easy to maintain, and safe to operate in a residential environment. Current experiments are focusing on Zn/I chemistry, but other aqueous chemistries could be used in the future. Instead of an ion exchange membrane, the battery uses readily attainable photo paper and is already showing similar order of magnitude performance to lab-developed cells.

Any components that aren’t off-the-shelf have been designed in FreeCAD. While they can be 3D printed, the researchers have found traditional milling yields better results which isn’t too surprising when you need something water-tight. More work is needed, but it is promising work toward a practical, DIY-able energy storage solution.

If you’re looking to build your own open source wind turbine or solar cells to charge up a home battery system, then we’ve got you covered. You can also break the chains of the power grid with off-the-shelf parts.

A FreeCAD sticker, a FreeCAD pencil, a Hackaday Jolly Wrencher SAO PCB and the board-to-be-encased next to each other

FreeCAD Foray: Shells For All Our PCBs

July 1, 2024 by 58 Comments

Are you the kind of hacker who tries to pick up FreeCAD, but doesn’t want to go through a tutorial and instead pokes around the interface, trying to transfer the skills from a CAD suite you’ve been using before? I’ve been there too, and in my experience, FreeCAD doesn’t treat such forays lightly. It’s a huge package that enables everything from architecture to robotics design, so if you just want a 3D-printed case for a PCB project, the hill can be steep. So let’s take that first simple project as an example, and see if it helps you learn a little bit of FreeCAD.

This board needs a case – badly.

As motivation, I recently built a USB-C PSU board that uses a DC PSU and does the USB-C handshaking to provide 20 V to a laptop. It is currently my only 100 W USB-C PSU, and my 60 W PSU just died, which is why I now use this board 24/7. I have brought it on two different conferences so far, which has highlighted a problem – it’s a board with tons of exposed contacts, which means that it isn’t perfectly travel-friendly, and neither it is airport-friendly – not that I won’t try and bring it anyway. So, currently, I have to watch that nothing shorts out – given the board has 3.3 V close to 20 V at 9 A, it’s a bit of a worry.

This means I have to design some sort of case for it. I was taught SolidWorks in the half a year that I spent in a university, and honestly, I’m tired of the licensing and proprietary format stuff. When it comes to more hobbyist-accepted tools like Fusion360, I just don’t feel like exchanging one proprietary software for another. So, FreeCAD is the obvious choice – apart from OpenSCAD, which I know and love, but I don’t always want to think up fifteen variable names for every silly little feature. That, and I also want to fillet corners every now and then.

For a full-open-source workflow, today’s PCB is designed with KiCad, too. Let’s see about installing FreeCAD, and the few things you need to import a KiCad board file into FreeCAD.

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FOSDEM Saved, With 3D Printing

February 9, 2024 by 23 Comments

If you were to consider what the most important component of a hacker event might be, the chances are you’d pick something that’s part of the program, the ambiance, or the culture. But as the organizers of FOSDEM in Brussels found out, what’s really the most important part of such an event is the toilet paper.

If you can’t keep the supplies coming, you’re in trouble, and since they only had one key for the dispensers across the whole event, they were heading for a sticky situation. But this is a hacker event, and our community is resourceful. The folks on the FreeCAD booth created a model of the key which they shared via the Ondsel collaboration tools, while those on the Prusa booth fired up their Prusa XL and ran off a set of keys to keep the event well supplied.

Perhaps for many of us, the act of running off a 3D model and printing it is such a mundane task as to be unremarkable — and indeed the speed at which they were able to do it points to it being a straightforward task for them. But the sight of a bunch of hardware hackers saving the event by doing what they do best is still one to warm the cockles of our hearts. We’re fairly certain it’s not the first time we’ve seen a bit of clandestine venue hacking save an event, but perhaps for the sake of those involved, we’d better not go into it.

Come For The PCB Holder, Stay For The Tour Of FreeCAD

November 26, 2023 by 10 Comments

PCB holders are great tools. Not only is the PCB Solder Fren from [PistonPin] a nice DIY design, it offers some insight into the parts design process with FreeCAD.

This design nicely demonstrates FreeCAD’s workflow for designing parts.

The PCB holder uses 3D-printed parts, M5 hardware, a length of 2020 aluminum extrusion, and one spring to create a handy and adjustable design that accommodates a variety of PCB sizes and shapes. If the ends of the extrusion are threaded, the end caps can be screwed in. Otherwise, a little glue ought to do the trick.

Want a little more insight into what making a part like this involves? [Jo Hinchliffe] at FreeCAD reached out to [PistonPin] for more detail and has a blog post explaining the workflow and steps involved in this part. As a bonus, STEP files and the FreeCAD project file are all included!

Not only is FreeCAD simple to use, but it’s also flexible enough to accommodate custom, niche extensions like a Rocketry workbench, so be sure to give it a look for your open-source CAD needs.

Throw FreeCAD Some Curves

August 12, 2023 by 43 Comments

[Mango Jelly] got a question from someone trying to model a phone box with a complex curved roof. We have to admit that when we saw it, we knew it would be hard to model well. Naturally, there are several ways it could be one, but [Mango Jelly] used the curves workbench in FreeCAD to produce a wireframe of the shape, and you can see how that works in the video below.

The curve bench didn’t sound familiar to us, and that’s because it is an add-on workbench. He starts with a sketch of a curve, constrained to be symmetrical. Then the draft workbench allowed a rotation to convert the curve into a nice skeleton of the curved roof.

The curves workbench can create a Gordon surface over that skeleton. You can extrude that into a solid object. There are still some details to add, though, and you’ll see how each part of the roof takes shape.

Watching videos like this reminds us that we use a small fraction of what FreeCAD can do. You’ll probably pick up at least one tip from this video. If you need a quick basic tutorial, try the one from [NovaSpirit]. Or, try a longer one.

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ChatGPT, The Worst Summer Intern Ever

July 26, 2023 by 71 Comments

Back when I used to work in the pharma industry, I had the opportunity to hire summer interns. This was a long time ago, long enough that the fresh-faced college students who applied for the gig are probably now creeping up to retirement age. The idea, as I understood it, was to get someone to help me with my project, which at the time was standing up a distributed data capture system with a large number of nodes all running custom software that I wrote, reporting back to a central server running more of my code. It was more work than I could manage on my own, so management thought they’d take mercy on me and get me some help.

The experience didn’t turn out quite like I expected. The interns were both great kids, very smart, and I learned a lot from them. But two months is a very tight timeframe, and getting them up to speed took up most of that time. Add in the fact that they were expected to do a presentation on their specific project at the end of the summer, and the whole thing ended up being a lot more work for me than if I had just done the whole project myself.

I thought about my brief experience with interns recently with a project I needed a little help on. It’s nothing that hiring anyone would make sense to do, but still, having someone to outsource specific jobs to would be a blessing, especially now that it’s summer and there’s so much else to do. But this is the future, and the expertise and the combined wisdom of the Internet are but a few keystrokes away, right? Well, maybe, but as you’ll see, even the power of large language models has its limit, and trying to loop ChatGPT in as a low-effort summer intern leaves a lot to be desired.

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