How To Try Generative Optimization At Home

Chairs, spokes on a wheel, bridges, and all kinds of other load-bearing objects are designed such that material is only present where it is needed. There’s a process by which the decisions about how much material to put and where is determined by computer, and illustrating this is [Adam Bender]’s short primer on how to use generative optimization in Autodesk’s Fusion 360 (which offers a variety of free licenses) using a wheel as an example.

Things start with a solid object and a definition of the structural loads expected. The computer then simulates the force (or forces) involved, and that simulation can be used to define a part that only has material where it’s really needed. The results can be oddly organic looking, and this process has been used to optimize spacebound equipment where every gram counts.

It’s far from an automated process, but it doesn’t look too difficult to navigate the tools for straightforward designs. [Adam] cautions that one should always be mindful of the method of manufacturing when designing the part’s final form, which is always good advice but especially true when making oddball shapes and curves.  To see the short process in action, watch the video embedded below.

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Design And Construction With Copper Pipe

Copper is a material with many applications; typically, it’s used for electrical wiring or in applications where good heat conductivity is a requirement. However, it can also make for an attractive material in furnishings, which [Andrei Erdei] decided to explore.

A render of the coffee table design, exported from OpenSCAD into Fusion360.

[Andrei]’s work began in OpenSCAD, where he wrote scripts to enable the quick and easy assembly of various designs. The modular nature of commercially-available copper pipe and fittings allows complex structures to be assembled, particularly if you’re a fan of 90-degree bends. The final renders of some of these designs are impressive, with the coffee table design a particular highlight. Staying conceptual wasn’t enough, however, so [Andrei] set out to build one of his designs. Constructing a table lamp shroud out of copper parts was successful, though the real components have flanges and other features that aren’t represented in the rendering.

It’s a project that shows the value of tools such as OpenSCAD to aid the design process before committing to cutting real-world materials. While the designs on screen aren’t perfect representations of what’s possible in reality, it still proves to be a useful guide.

We’re a fan of the aesthetic, and would love to see more done with copper pipe as a construction kit. Global ore prices may limit experimentation, however. Alternatively, you can always harvest the metal from scrap!

Build Your Own Tools For More Power

Building something on your own usually carries with it certain benefits, such as being in full control over what it is you are building and what it will accomplish, as well as a sense of pride when you create something that finally works just the way you want it. If you continue down that path, you may eventually start making your own tools to help build your other creations, and if you also have some CAD software you can make some very high quality tools like this belt grinder.

This build comes to us from [Emiel] aka [The Practical Engineer] who is known for his high quality solenoid engines. His metal work is above and beyond, and one thing he needed was a belt grinder. He decided to make a 3D model of one in CAD and then build it from scratch. The build video goes through his design process in Fusion 360 and then the actual build of this beast of a machine. The motor is 3.5 horsepower which, when paired with a variable frequency drive, can provide all of his belt grinding needs.

[Emiel]’s videos are always high quality, and his design process is easy to follow as well. We’re always envious of his shop as well, and it reminds us a lot of [Eric Strebel] and his famous designs.

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Hackaday Links: October 13, 2019

Trouble in the Golden State this week, as parts of California were subjected to planned blackouts. Intended to prevent a repeat of last year’s deadly wildfires, which were tied in part to defective electrical distribution equipment, the blackouts could plunge millions in the counties surrounding Sacramento into the dark for days. Schools have canceled classes, the few stores that are open are taking cash only, and hospitals are running on generators. It seems a drastic move for PG&E, the utility that promptly went into bankruptcy after being blamed for last year’s fires, but it has the support of the governor, so the plan is likely to continue as long as the winds do. One group is not likely to complain, though;  California amateur radio operators must be enjoying a greatly decreased noise floor in the blackout areas, thanks to the loss of millions of switch-mode power supplies and their RF noise.

Good news, bad news for Fusion 360 users. Autodesk, the company behind the popular and remarkably capable CAD/CAM/CAE package, has announced changes to its licensing scheme, which went into effect this week. Users no longer have to pay for the “Ultimate” license tier to get goodies like 5-axis machining and generative design tools, as all capabilities are now included in the single paid version of Fusion 360. That’s good because plenty of users were unwilling to bump their $310 annual “Standard” license fee up to $1535 to get those features, but it’s bad because now the annual rate goes to $495. In a nice nod to the current userbase, those currently on the Standard license, as well as early adopters, will get to keep the $310 annual rate as long as they renew, and The $495 pricing tier went into effect in November of 2018, while anyone still on the $310 annual price was grandfathered in (and will remain to be). At that time there was still a $1535 tier called Ultimate, whose price will now be going away but the features remain in the $495 tier which is now the only pricing option for Fusion 360. Ultimate users will see a $1040 price drop. As for the current base of freeloaders like yours truly, fear not: Fusion 360 is still free for personal, non-commercial use. No generative design or tech support for us, though. (Editor’s Note: This paragraph was updated on 10/14/2019 to clarify the tier changes after Autodesk reached out to Hackaday via email.)

You might have had a bad day at the bench, but was it as bad as Román’s? He tipped us off to his nightmare of running into defective Wemos D1 boards – a lot of them. The 50 boards were to satisfy an order of data loggers for a customer, but all the boards seemed caught in an endless reboot loop when plugged into a USB port for programming. He changed PCs, changed cables, but nothing worked to stop the cycle except for one thing: touching the metal case of the module. His write up goes through all the dead-ends he went down to fix the problem, which ended up being a capacitor between the antenna and ground. Was it supposed to be there? Who knows, because once that cap was removed, the boards worked fine. Hats off to Román for troubleshooting this and sharing the results with us.

Ever since giving up their “Don’t be evil” schtick, Google seems to have really embraced the alternative. Now they’re in trouble for targeting the homeless in their quest for facial recognition data. The “volunteer research studies” consisted of playing what Google contractors were trained to describe as a “mini-game” on a modified smartphone, which captured video of the player’s face. Participants were compensated with $5 Starbucks gift cards but were not told that video was being captured, and if asked, contractors were allegedly trained to lie about that. Contractors were also allegedly trained to seek out people with dark skin, ostensibly to improve facial recognition algorithms that notoriously have a hard time with darker complexions. To be fair, the homeless were not exclusively targeted; college students were also given gift cards in exchange for their facial data.

For most of us, 3D-printing is a hobby, or at least in service of other hobbies. Few of us make a living at it, but professionals who do are often a great source of tips and tricks. One such pro is industrial designer Eric Strebel, who recently posted a video of his 3D-printing pro-tips. A lot of it is concerned with post-processing prints, like using a cake decorator’s spatula to pry prints off the bed, or the use of card scrapers and dental chisels to clean up prints. But the money tip from this video is the rolling cart he made for his Ultimaker. With the printer on top and storage below, it’s a great way to free up some bench space.

And finally, have you ever wondered how we hackers will rebuild society once the apocalypse hits and mutant zombie biker gangs roam the Earth? If so, then you need to check out Collapse OS, the operating system for an uncertain future. Designed to be as self-contained as possible, Collapse OS is intended to run on “field expedient” computers, cobbled together from whatever e-waste can be scrounged, as long as it includes a Z80 microprocessor. The OS has been tested on an RC2014 and a Sega Master System so far, but keep an eye out for TRS-80s, Kaypros, and the odd TI-84 graphing calculator as you pick through the remains of civilization.

Computer Optimized 3D Printed Bookshelves

[Thomas] does a lot of interesting experiments with 3D printing and lately, he’s been using the free version of Fusion 360 to do topology optimization. He started with a blocky bookshelf bracket and let the software analyze the loads so it can remove pieces that don’t contribute a lot to the bracket’s strength. This uses less material, prints faster, and — [Thomas’] biggest goal — looks cool.

If you know [Thomas] you know he didn’t just hope the brackets would be strong enough. He made prototypes and destroyed them in testing. Despite being printed in a poor orientation for strength, the models held a good bit of weight.

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Fusion 360 For 3D-Printing Hack Chat

Join us on Wednesday 12 June 2019 at noon Pacific for the Fusion 360 for 3D-Printing Hack Chat with Vladimir Mariano!

There’s no way to overstate the importance of the design and manufacturing tools we now all use on a daily basis. What once took a well-equipped machine shop and years of experience to accomplish can now be designed using free software and built using 3D-printers and a host of other CNC tools, all right on the desktop.

The number of doors this manufacturing revolution has opened are uncountable, and through his popular Desktop Makes YouTube channel and other outlets, Vladimir’s mission is to help people navigate through this world and discover their inner maker. He co-founded the Fairfield County Maker’s Guild in Connecticut and founded the CT Robotics Academy. From 3D-printing and design to electronics and programming, Vladimir teaches it all. He’ll join us for the Hack Chat to discuss the desktop manufacturing revolution in general, plus answer your questions on his main tools, Fusion 360 and 3D-printing.

join-hack-chatOur Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday June 12 at 12:00 PM Pacific time. If time zones have got you down, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.

 

Autodesk Fusion 360 Hack Chat

Join us Wednesday at noon Pacific time for the Autodesk Fusion 360 Hack Chat!

Most of us have a collection of tools that we use for the various mechanical, electronic, and manufacturing tasks we face daily. But if you were asked to name one tool that stretches across all these spaces, Autodesk Fusion 360 would certainly spring to mind. Everyone from casual designers of 3D-printed widgets to commercial CNC machine shops use it as an end to end design solution, and anyone who has used it over the last year or so knows that the feature set in Fusion is expanding rapidly.

Matt, who goes by technolomaniac on Hackaday.io, is Director of Product Development for EAGLE, Tinkercad, and Fusion 360 at Autodesk. He’ll drop by the Hack Chat this week to discuss your questions about:

  • All the Autodesk design software components, from EAGLE to Fusion and beyond
  • Future plans for an EAGLE-Fusion integration
  • Support for manufacturing, including additive, CNC, and even mold making
  • Will there ever be “one design tool to rule them all?”

You are, of course, encouraged to add your own questions to the discussion. You can do that by leaving a comment on the Autodesk Fusion 360 Hack Chat page and we’ll put that in the queue for the Hack Chat discussion.

join-hack-chatOur Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, April 10, at noon, Pacific time. If time zones have got you down, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.