FDM Printing With Resin Update

March 4, 2023 by Al Williams 15 Comments

[Proper Printing] is at it again. He’s trying to perfect his hybrid printer that works like an FDM printer but uses UV-curable resin gel instead of filament. You can see the latest update video below. If you missed our take on his early attempts, you might want to catch up with those earlier videos first.

The latest update brings a new nozzle, an improved light source, and changes to the formula of the resin. The nozzle and light source improvements hinge on conical lenses that convert the laser beams from a spot to a ring. The initial nozzles looked like the business end of a syringe, but this wasn’t very stable. The new video shows a conventional nozzle which also had some issues. This resulted in a custom-made nozzle that solved all the issues with the conventional nozzle and the syringe tips.

The resin formula is particularly crucial. The second attempt used resin with glass beads to give thickness. That wasn’t without problems, though, so it was switched this time with fused silica, as suggested by some comments on a previous video. They also used aggressive mixing and air removal. The consistency of the previous resins was that of a paste, but according to the video, the new mixture is more like a gel.

At some point, things started going badly. There were several equipment failures. Exasperated, he was ready to give up and was editing the video when he had an epiphany. We’re glad he didn’t give up because the new results are pretty impressive.

These printers remind us of some strange laser CNC. It also reminds us a little of people curing resin outside of the normal print process.

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More Detail On That Fantastic Lego OLED Brick

December 20, 2022 by Dan Maloney 39 Comments

It’s always great when we get a chance to follow up on a previous project with more information, or further developments. So we’re happy that [“Ancient” James Brown] just dropped a new video showing the assembly of his Lego brick with a tiny OLED screen inside it. The readers are too, apparently — we got at least half a dozen tips on this one.

We’ve got to admit that this one’s a real treat, with a host of interesting skills on display. Our previous coverage on these bedazzled bricks was disappointingly thin on details, and now the original tweets even seem to have disappeared entirely. In case you didn’t catch the original post, [James] found a way to embed a microcontroller and a remarkably small OLED screen into a Lego-compatible brick — technically a “slope 45 2×2, #3039” — that does a great job of standing in for a tiny computer monitor.

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Cardboard Game Tokens Become Shiny Click-Clacks With DIY Treatment

November 30, 2022 by Donald Papp 30 Comments

Tabletop games and cardboard tokens go hand-in-hand for a good reason: they are economical and effective. However, their tactile attributes leave a little to be desired. There’s something really great about high-quality pieces possessing a shiny, pleasing smoothness and click-clack handling that cardboard simply can’t deliver, but that all changes with [Dzhav]’s simple method for converting cardboard tokens into deluxe versions of themselves with a little work and a resin coating.

The result is a token with a crystal-clear, smooth, and slightly-convex coating of hardened resin on it. They feel (and sound) like plastic, rather than cardboard. The resin used is a two-part clear jewelry resin, used for casting things like pendants. It benefits from a long working time and unlike UV-cured resin (like the SLA 3D printer resin) it won’t be affected by light.

Careful application of resin relies on surface tension to prevent messes.

Like with most things, good results come from careful preparation and technique. [Dzhav] suggests preparing the tokens by sanding the edges completely smooth with fine sandpaper, then using a black marker to color them. Then, tokens are coated one side at a time with a paintbrush and correctly-mixed resin: while holding a token down with a toothpick, resin is brushed right to (but not over) the edges. Then, additional resin can be dropped in the center of the token, and gravity and surface tension will work together to ensure an even coating that doesn’t drip.

After the resin has had plenty of time to cure, the tokens are flipped over and the process repeated. The end result are tokens with both sides coated in a nice, smooth, ever-so-slightly-convex shield of resin.

They look fantastic, and sound even better. Turn up your volume and play the two-second video embedded below to listen for yourself. And when you’re ready for another gamer that didn’t settle for what was in the box, check out this redesigned Catan version.

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Madness Or Genius? FDM Printing With Resin

November 17, 2022 by Al Williams 29 Comments

We aren’t sure what made him think of it, but [Proper Printing] decided to make an FDM printer lay down resin instead of filament. Why? We still aren’t sure, but we admire the effort nonetheless. In principle, extruding resin shouldn’t be much different than other liquid things you print like icing or concrete. Then you’d need to UV-cure the viscous liquid quickly. In fact, they wound up making up a paste-like resin using several chemicals and a filler.

Armed with the paste, it would seem like the big obstacles would be over. Instead of part cooling fans, the printer now has two laser heads focused on the print area. Printing in vase mode avoids some problems, but the first few attempts were not very successful.

With a bit of perseverance, the setup did work — for a while. More fine tuning got acceptable results. However, he eventually changed the filler material and got a passable Benchy to print. Nothing to be proud of, but recognizable. Honestly, we were surprised that the laser’s didn’t cure the material still inside the nozzle and cause terrible clogs.

Why put this much effort into doing this? We have no idea. Should you try it? Probably not. Of course, being able to print a paste has its own value. Perhaps delivering glue or solder paste, for example. But you generally won’t need to make tall prints with that kind of material. Then again, we’ve never been opposed to doing something “just because.”

After all, why make a musical instrument out of a Game Boy? Why make a modem with tin cans? You might as well extrude resin.

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Toilet Paper Tube Pulls Dissolved Resin From IPA, Cures It For Disposal

October 12, 2022 by Donald Papp 53 Comments

SLA 3D printing with resin typically means rinsing parts with IPA (isopropyl alcohol). That process results in cloudy, used IPA containing a high concentration of dissolved resin. The dual goals of cleaning and reusing IPA are important ones, and we have to say, [Jan Mrázek]’s unusual experiment involving a UV source and slowly-rotating paper tube to extract and cure dissolved resin might look odd, but the results are definitely intriguing.

Dissolved resin successfully pulled from IPA and cured onto a cardboard roll. This particular one rotated a bit too quickly, trapping IPA in the curing process and yielding a slightly rubbery wad instead of a hard solid.

The best way to dispose of liquid resin is to cure it into a solid, therefore making it safe to throw away. But what about resin that has been dissolved into a cleaning liquid like IPA? [Jan] felt that there was surely a way to extract the dissolved resin somehow, which would also leave the IPA clean for re-use. His solution? The device shown here, which uses a cardboard tube to pull dissolved resin from an IPA bath and a UV source to cure it onto the tube.

Here’s how it works: the tube’s bottom third sits in dirty IPA, and UV LEDs shine on the top of the tube. The IPA is agitated with a magnetic stirrer for best results. A motor slowly rotates the cardboard tube; dissolved resin gets on the tube at the bottom, UV cures it at the top, and the whole thing repeats. Thin layers of cured resin slowly build up, and after long enough, the roll of cured resin can be thrown away and the IPA should be clean enough for reuse.

So far it’s a pretty successful test of a concept, but [Jan] points out that there are still some rough edges. Results depend on turning the tube at a good rate; turning it too quickly results in IPA trapped with the cured residue. On the plus side, the UV source doesn’t need to be particularly powerful. [Jan] says that Ideally this would be a device one could run in a sealed container, cleaning it over one or two days.

Resin printing is great, but it’s a messy process, so anything that makes it less wasteful is worth checking out. Got any ideas for improving or building on this concept? If so, don’t keep ’em to yourself! Let us know in the comments.

PCB-Filled Dream Desk Will Only Get Cooler With Age

October 7, 2022 by Kristina Panos 27 Comments

We all have one. Maybe you’re sitting at it now, or just wishing you were — that perfect desk. You know the one — a place for everything and everything in its place, ample acreage, specialized storage, and top-notch looks. Oh, and blinkenlights. Can’t forget those.

It took four months of hard work, but [Build XYZ]’s dream desk has been finely fabricated into fruition. There’s a lot to unpack with this build, which you can appreciate after the break, but it all started with a donated up/down desk from Progressive Desk. After building the base and putting it through its body weight-driven paces, [Build XYZ] set about making the perfect top, which, as you can see, highlights an assortment of PCBs by encasing them for eternity in resin.

But don’t let your admiration stop there, because the woodworking is just as much a part of the show. In addition to the functional blinkenlights that notify [BuildXYZ] when it’s time to stop working for the day or just take a break, there’s a working wireless charger hiding among the FR4. We can’t wait to look back on this desk in 20 years or so and we also can’t wait to see how PCBs will change over the next 20 years.

This tightly-produced video is a fascinating look into the process of forever immortalizing things in resin. So much resin, in fact, that [Build XYZ] came up a gallon short during the pour and had to wait an excruciatingly long time before more resin showed up. Seeing as how you totally can’t tell at all in the final build, we have maximum respect for [Build XYZ]’s inclusion of this part in the first place, which serves as a warning to the rest of us.

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When 3D Printing Gears, It Pays To Use The Right Resin

September 26, 2022 by Donald Papp 9 Comments

There are plenty of resins advertised as being suitable for functional applications and parts, but which is best and for what purpose?

According to [Jan Mrázek], if one is printing gears, then they are definitely not all the same. He recently got fantastic results with Siraya Tech Fast Mecha, a composite resin that contains a filler to improve its properties, and he has plenty of pictures and data to share.

[Jan] has identified some key features that are important for functional parts like gears. Dimensional accuracy is important, there should be low surface friction on mating surfaces, and the printed objects should be durable. Of course, nothing beats a good real-world test. [Jan] puts the resin to work with his favorite method: printing out a 1:85 compound planetary gearbox, and testing it to failure.

The results? The composite resin performed admirably, and somewhat to his surprise, the teeth on the little gears showed no signs of wear. We recommend checking out the results on his page. [Jan] has used the same process to test many different materials, and it’s always updated with all tests he has done to date.

Whether it’s working out all that can go wrong, or making flexible build plates before they were cool, We really admire [Jan Mrázek]’s commitment to getting the most out of 3D printing with resin.