We’ll admit that most of the Hackaday staff wouldn’t get too far on a skateboard, but that doesn’t mean we can’t appreciate the impressive DIY wheels that [Chris McCann] has managed to cast using 3D printed molds. From unique color combinations to experimental materials, the process certainly opens up some interesting possibilities for those looking to truly customize their rides. Though it’s worth noting there’s a certain element of risk involved; should a set of homemade wheels fail at speed, it could go rather poorly for the rider.
Both the STL and STEP files for the mold have been released under the Creative Commons Attribution 4.0 license, meaning anyone with a 3D printer can follow along at home. Unfortunately, it’s not quite as simple as clicking print and coming back to a usable mold. Because of the layer lines inherent to FDM 3D printing, the inside of the mold needs to be thoroughly sanded and polished. [Chris] mentions that printing the mold in ABS and using vapor smoothing might be a workable alternative to elbow grease and PLA, but he hasn’t personally tried it yet.
Once you’ve got the three part mold printed, smoothed, and coated with an appropriate release agent like petroleum jelly, it’s time to make some wheels. The core of each wheel is actually 3D printed from PETG, which should give it pretty reasonable impact resistance. If you have access to a lathe, producing aluminum cores shouldn’t be too difficult either. With the core loaded into the mold, urethane resin is poured in through the top until all the empty space is filled.
But you’re not done yet. All those little air bubbles in the resin need to be dealt with before it cures. [Chris] puts his filled molds into a pressure chamber, though he mentions that vacuum degassing might also be a possibility depending on the urethane mixture used. After everything is solidified, the mold can easily be taken apart to reveal the newly cast wheel.
Advances in filaments for FDM 3D printers have come in leaps and bounds over the past few years, and carbon fibre (CF) reinforced filament is becoming a common sight. Robotics extraordinaire [James Bruton] got his hands on some CF reinforced PLA, and ended up building a completely over-engineered 3D printed skateboard. (Video, embedded below.)
[James] started by printing some test pieces with a 0.5 mm and a big 1.2 mm nozzle with and without the CF, which he subjected to cantilever deflection tests. The piece with CF was 20% stiffer than without.
[James] then built an extremely strong and cool looking skateboard deck with alternating section of the CF PLA and toughened PLA, totalling 2.7 kg of filament. It was extremely strong, so after bolting on a set of trucks and wheels, he did some mild riding at a local skate park, where it survived without any problems. He admits it was completely over-engineered, but points out in that the internal cavities in the deck is the perfect place for batteries on an electric long board.
Designing something from the ground up with the strength and weaknesses 3D printing in mind, leads to some very interesting and innovative designs, of which this is a perfect example, and we hope to see many more like it. We’ve featured a number of [James]’ project, including the remote controlled bowling ball he built for [Mark Rober] and his impressive OpenDog and Start Wars robots.
Initial results were disheartening – the skateboard relies on various chips of Chinese origin for which documentation proved impossible to come by. However, as it turned out, the board and controller communicated using the common NRF24L01+ transceiver.
Initial work focused on understanding the pairing process and message protocol. With that done, [Timo] decided the best course of action was to redevelop a controller from scratch, using an Arduino Nano and NRF24L01+ to do the job. [Timo]’s Open esk8 controller improves driveability by removing delays in message transfer, as well as improving on the feel of the controller with a 3D printed chassis redesign.
[Timo] now has a much more usable skateboard, and has racked up over 200 miles in testing since the build. However, if you fancy converting your existing board to electric, check out this project.
Have you ever looked at your cat and thought “You know, my kitten really needs an electric skateboard!” Probably not, but this seems to have happened to [Kim Pimmel] while looking at his cat MIDI, so he decided to build one. This process involved building a simple, low powered skateboard with a Feather mainboard and motor controller combined with a laser-cut switch mechanism. When [Kim] puts a treat into the mechanism, the cat pulls the switch and the skateboard moves forward, moving into a brave new e-skateboarding feline future. MIDI looks somewhat unimpressed by this whole business, but I suspect that as long as the treats keep coming, he will be happy to keep on truckin’. Now, if he can just figure out how to persuade the cat to ollie, we will be really getting somewhere.
Feline tomfoolery seems to be a regular pastime here on these pages, and more than just a quest for easy moggy-driven clickbait. A lot of cat feeders and cat finders abound, but this project isn’t the only cat-operated one. Our readers’ pets can probably spot an Arduino a mile away by now.
[Nate] has made snowboarding cool with his Bluetooth connected board. Using 202 WS2812 LEDs carefully wrapped around the edge of the board and sealed with a conformal coating, it’s bright and waterproof. It’s controlled with an Arduino Nano and a Bluetooth classic board, as well as a large swappable USB battery bank; he can get roughly four hours of life at full brightness on his toy.
Where it gets even cooler is with a six-axis gyro connected to the Nano, which tracks the board movement, and the lights respond accordingly, creating cool patterns based on his speed, angles, and other factors. The app used to control this intense ice-rider is a custom app written using MIT App Inventor, which has the ability to work with Bluetooth classic as well as BLE. This came in handy when he made the 100-LED skateboard, which is based on a Feather with BLE and a large LiPo battery. The challenging part with the skateboard was making the enclosure rugged enough (yet 3D printed) to withstand terrain that is a lot less fluffy than snow.
[Matt Obal] had a problem. The local skatepark was too far to skateboard, but close enough to bike. Carrying a skateboard on a bicycle is a rather awkward (and unsafe) maneuver. [Matt’s] answer to the problem is Truck Stop, a bicycle mounted skateboard carrier he developed and is manufacturing himself.
[Matt’s] work on Truck Stop began about a year ago, with his purchase of a 3D printer. He designed a seat back mounted device that secures the skateboard by wedging between the truck and the board itself. The design is printed in PLA and is hollow. Truck Stop’s strength comes from being filled with resin and fiberglass cloth.
If you’ve worked with resin, you probably know that some formulas get hot while they harden. This caused a few melted prints until [Matt] figured out that a dunk in cold water at the right time would allow the resin to complete it’s hardening process while keeping the heat below the melting temperature of PLA. He’s since switched to a different resin formula that generates less heat.
[Matt] is selling the Truck Stop at his website, and spent quite a bit of time working on a silicon mold so he could cast as many mounts as he wanted. The problem was fiberglass poking through the final cast part. In the end, he decided to stick with the resin filled PLA of his prototypes.
[Patrick] is using a capable 380KV Propdrive motor, capable of pushing him up to 30mp/h! A waterproof 120A speed controller and 6000mAh, 22.2V LiPo battery slim enough to fit under the board give the motor the needed juice. He ended up buying the cheapest RF receiver and remote combo to control the board, but it fit the all-important “want electric long board now” criterion.