Unique 3D Printer Has A Print Head With A Twist

December 2, 2024 by Dan Maloney 26 Comments

If you’re used to thinking about 3D printing in Cartesian terms, prepare your brain for a bit of a twist with [Joshua Bird]’s 4-axis 3D printer that’s not quite like anything we’ve ever seen before.

The printer uses a rotary platform as a build plate, and has a linear rail and lead screw just outside the rim of the platform that serves as the Z axis. Where things get really interesting is the assembly that rides on the Z-axis, which [Joshua] calls a “Core R-Theta” mechanism. It’s an apt description, since as in a CoreXY motion system, it uses a pair of stepper motors and a continuous timing belt to achieve two axes of movement. However, rather than two linear axes, the motors can team up to move the whole print arm in and out along the radius of the build platform while also rotating the print head through almost 90 degrees.

The kinematic possibilities with this setup are really interesting. With the print head rotated perpendicular to the bed, it acts like a simple polar printer. But tilting the head allows you to print steep overhangs with no supports. [Joshua] printed a simple propeller as a demo, with the hub printed more or less traditionally while the blades are added with the head at steeper and steeper angles. As you can imagine, slicing is a bit of a mind-bender, and there are some practical problems such as print cooling, which [Joshua] addresses by piping in compressed air. You’ll want to see this in action, so check out the video below.

This is a fantastic bit of work, and hats off to [Joshua] for working through all the complexities to bring us the first really new thing we’ve seen in 3D printing is a long time.

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Pen Plotter Uses Polar Coordinates

August 23, 2023 by Bryan Cockfield 12 Comments

To keep track of a location in a two-dimensional space, two measurements are needed. Most of the time, we would naturally think to do this by the Cartesian method, measuring position along one axis and then again along a second axis. But this isn’t the only way of keeping track of position. Polar coordinates, where the distance from the origin and an angle are used as the two measurements, works just as well, and sometimes can be a preferred method. This pen plotter tosses the expected Cartesian methodology we would typically expect in favor of this polar system.

The first prototype that [André] built was a good proof of concept. A pen attached to a movable carriage on a single rotating arm produced passable drawings, but as all prototypes go this one needed some refinement. Limit switches at the ends of the table, as well as within the arm, served to orient the plotter so that it didn’t manually need to be zeroed out every time. A linear actuator was added to give finer control over the pen’s pressure on the table, and finally an encoder was added to the base of the plotter to more accurately correct positional errors in the rotating arm mechanism.

With everything said and done, the polar coordinate plotter seems to work just as well as its Cartesian cousins might, orienting it like this has some advantages as well. Specifically, it is more adapted to drawing curves or circles than an X-Y device might be able to, like we saw with this similar sand-drawing plotter. Also, if allowed to rotate its entire 360-degree reach instead of just the 90 degrees shown in the video, a machine like this could theoretically reach a wider workspace more easily than other plotters.

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Texture Map GCode Directly In Blender With NozzleBoss

March 31, 2022 by Dave Rowntree 5 Comments

We’ve seen this funky dual disk polar printer already recently, but [Heinz Loepmeier] has been busy working on it, so here’s an update. The primary focus here is nozzleboss, a blender plugin which enables the surface textures of already sliced objects to be manipulated. The idea is to read in the gcode for the object, and convert it to an internal mesh representation that blender needs in order to function. From there the desired textures can be applied to the surfaces for subsequent stages to operate upon. One trick that nozzleboss can do is to create weight maps to tweak the extrusion flow rate or print velocity value according to the pixel value at the surface — such ‘velocity painting’ can produce some very subtle surface effects on previously featureless faces. Another trick is to use the same weight maps and simply map colours to blender text blocks which are injected into the gcode at export time. These gcode blocks can be used swap tool heads or extruders, enabling blending of multiple filament colours or types in the same object.

Some nice examples of such printing manipulation can be seen on [Heinz’s] instagram page for the project. So, going back to the hardware again, the first video embedded below shows the ‘dual disk polar printer’ fitted with a crazy five-extruders-into-one-nozzle mixing hotend setup, which should be capable of full CMYK colour mixing and some. The second video below shows an interesting by-product of the wide horizontal motion range of the machine, that the whole printing area can be shifted to a nozzle at the other end of the gantry. This enables a novel way to switch extruders, by just moving the whole bed and print under the nozzle of interest! One final observation — is that of the print surface — it does look rather like they’re printing direct onto a slab of marble, which I think is the first time we’ve seen that.

Interesting printer designs are being worked on a lot these days, here’s a really nice 5-axis prusa i3 hack, and if you want to stay in the cartesian world, but your desktop machine is just too small, then you can always supersize it.

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Plotter Uses Dual Disks

February 19, 2021 by Al Williams 19 Comments

If you want to move a pen (or a CNC tool, or a 3D printing hot end) in the X and Y plane, your choices are typically pretty simple. Many machines use a simple cartesian XY motion using two motors and some sort of linear drive. There’s also the core-XY arrangement where two motors move belts that cause the head to travel in two directions. Delta printers use yet another arrangement, but one of the stranger methods we’ve seen is the dual disk polar printer which — as its name implies — uses two rotating disks.

The unique mechanism uses one motor to rotate a disk and another motor to rotate the entire assembly. The print head — in this case a pencil — stays stationary. as you can see in the video below.

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Sensor Filters For Coders

September 6, 2019 by Pat Whetman 35 Comments

Anybody interested in building their own robot, sending spacecraft to the moon, or launching inter-continental ballistic missiles should have at least some basic filter options in their toolkit, otherwise the robot will likely wobble about erratically and the missile will miss it’s target.

What is a filter anyway? In practical terms, the filter should smooth out erratic sensor data with as little time lag, or ‘error lag’ as possible. In the case of the missile, it could travel nice and smoothly through the air, but miss it’s target because the positional data is getting processed ‘too late’. The simplest filter, that many of us will have already used, is to pause our code, take about 10 quick readings from our sensor and then calculate the mean by dividing by 10. Incredibly simple and effective as long as our machine or process is not time sensitive – perfect for a weather station temperature sensor, although wind direction is slightly more complicated. A wind vane is actually an example of a good sensor giving ‘noisy’ readings: not that the sensor itself is noisy, but that wind is inherently gusty and is constantly changing direction.

It’s a really good idea to try and model our data on some kind of computer running software that will print out graphs – I chose the Raspberry Pi and installed Jupyter Notebook running Python 3.

The photo on the left shows my test rig. There’s a PT100 probe with it’s MAX31865 break-out board, a Dallas DS18B20 and a DHT22. The shield on the Pi is a GPS shield which is currently not used. If you don’t want the hassle of setting up these probes there’s a Jupyter Notebook file that can also use the internal temp sensor in the Raspberry Pi. It’s incredibly quick and easy to get up and running.

It’s quite interesting to see the performance of the different sensors, but I quickly ended up completely mangling the data from the DS18B20 by artificially adding randomly generated noise and some very nasty data spikes to really punish the filters as much as possible. Getting the temperature data to change rapidly was effected by putting a small piece of frozen Bockwurst on top of the DS18B20 and then removing it again.

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Polar Platform Spins Out Intricate String Art Portraits

February 23, 2019 by Dan Maloney 14 Comments

We have semi-fond memories of string art from our grade school art class days. We recall liking the part where we all banged nails into a board, but that bit with wrapping the thread around the nails got a bit tedious. This CNC string art machine elevates the art form far above the grammar school level without all the tedium.

Inspired by a string art maker we recently feature, [Bart Dring] decided to tackle the problem without using an industrial robot to dispense the thread. Using design elements from his recent coaster-creating polar plotter, he built a large, rotating platform flanked by a thread handling mechanism. The platform rotates the circular “canvas” for the portrait, ringed with closely spaced nails, following G-code generated offline. A combination of in and out motion of the arm and slight rotation of the platform wraps the thread around each nail, while rotating the platform pays the thread out to the next nail. Angled nails cause the thread to find its own level naturally, so no Z-axis is needed. The video below shows a brief glimpse of an additional tool that seems to coax the threads down, too. Mercifully, [Bart] included a second fixture to drill the hundreds of angled holes needed; the nails appear to be inserted manually, but we can think of a few fixes for that.

We really like this machine, both in terms of [Bart]’s usual high build-quality standards and for the unique art it creates. He mentions several upgrades before he releases the build files, but we think it’s pretty amazing as is.

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Make An Impression At The Bar With A CNC Coaster Plotter

December 26, 2018 by Dan Maloney 22 Comments

If you’re anything like us, your success with the opposite sex at the bar wasn’t much to brag about. But imagine if you had only had this compact CNC polar plotter and could have whipped up a few custom coasters for your intended’s drink. Yeah, that definitely would have helped.

Or not, but at least it would have been fun to play with. This is actually an improved version of [bdring]’s original “Polar Coaster”. Version 2 is really just a more compact and robust version of the original. The new one has a custom controller for the steppers and pen-lift servo, and everything is mounted neatly to the main PCB. Where the original used a timing belt to drive the platter, the new one uses 3D-printed helical gears, and the steppers have been replaced by slimmer motors. It even has an SD card and smartphone UI, and the coasters look pretty good.

There’s no video of the new one, but you can see its predecessor in action below and imagine the possibilities. Snap a picture and have a line art rendition of someone plotted while you’re waiting for drinks? Just remember not to take any laser engraved wooden nickels.

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