3D printing is pretty awesome

Scythe

<div class="IPBDescription">Pics inside</div>So I'm a member of <a href="http://hsbne.org/" target="_blank">Hackerspace Brisbane</a>. One of our projects over the last few months is building a 3D printer.

<img src="http://www.tjhowse.com/hackerspace/mendel/mendel01.jpg" border="0" class="linked-image" />
This is not ours, this is the printer that our printer was printed on.

It's called a <a href="http://reprap.org/wiki/Main_Page" target="_blank">Reprap</a>, specifically the Mendel. It's a machine designed to heat and extrude a filament of ABS (Lego plastic) or PLA (biodegradable cornstarch plastic) in a shape, layer upon layer, to build a 3d object. There are other 3d printers out there, but the goal of the Reprap project is to make a <b>printer that can print itself</b>. Several times throughout this project we've used a half-functional printer to print a replacement part for one that nearly broke during the print.

Just recently we've got ours working pretty well and we've started printing parts to build another printer. Yesterday I thought I'd try printing something I designed from scratch. I bought a Nexus One a few months ago, so I decided to design and print a dock for it. I used a program named <a href="http://openscad.org/" target="_blank">OpenSCAD</a> to build the 3d model. OpenSCAD is great because it allows you to define the model in terms of geometric primitives, their orientation and intersections. You can set two shapes to join to eachother where they touch, or have one take a bite out of another. I basically created a rough 3d model of the N1, intersected it with a dock-shaped solid block and said "subtract the N1 shape from the block". I was left with a N1-sized cavity. <a href="http://www.tjhowse.com/hackerspace/mendel/n1_dock/n1_dock_1.scad.txt" target="_blank">Here's</a> the code I used to generate the model.

<img src="http://www.tjhowse.com/hackerspace/mendel/n1_dock/dock.png" border="0" class="linked-image" />

From here it was a matter of exporting the model to an STL model file, then importing this into the Reprap software to turn it into a toolpath for the extruder. I then clicked print.

The result:

<img src="http://www.tjhowse.com/hackerspace/mendel/n1_dock/n1_dock_03.jpg" border="0" class="linked-image" />
Argh!

After cleaning off the trailing stringy bits:

<img src="http://www.tjhowse.com/hackerspace/mendel/n1_dock/n1_dock_07.jpg" border="0" class="linked-image" />

<img src="http://www.tjhowse.com/hackerspace/mendel/n1_dock/n1_dock_09.jpg" border="0" class="linked-image" />

The top of the backrest got truncated due to mechanical limits of the printer. It can't print tall objects near the edge of the print bed. If I'd set it to print in the middle of the platform it would've been fine.

More pics <a href="http://www.tjhowse.com/hackerspace/mendel/n1_dock/" target="_blank">here</a>.

--Scythe--

Svenpa

3d printers are cool, I've seen some before on the webs. I can't imagine how the heck you are supposed to make a printer print itself with what seems like rather dodgy print substance. I assume it cools almost instantly when it comes out? How sturdy is it and does it require any after-printing work? Like, coating it with something?

Scythe

It stays warm enough to adhere to the previous layer. You'd be surprised how strong this stuff is; if I printed a cube roughly the size of that dock I'm sure it could support my weight. The only after-print work required is cleaning off the spruey bits and clearing out any chaff in the holes leftover from printing. If you really need strength you can soak the whole thing in superglue and then put it in a bicarb bath to cure it. It stays a bit goopy in the centre but the outside shell becomes a bit stronger.

--Scythe--

Tykjen

Pretty awesome indeed. Kudos

Kouji_San

Hehe that's pretty cool, now print a Gorge action figure!

monopolowa

I got to see one of these at Lockheed Martin once (class field trip 10+ years ago). They use it to manufacture wings for testing in their wind tunnel, but they also had some neat trinkets (I got to take home a triangle-pyramid with a ball in the center, and they showed us part of their chess set - the rook had a staircase on the inside)

IIRC, the one they used would create layers using resin hardened by lasers

Chris0132

We have some at university, I think they run on a sort of silica dust and the result is a bit like sandstone.

Konohas Perverted Hermit

I personally liked using CNC machines. Not the lathes, but the routers and milling machines. Anything on a lathe I do by hand.

monopolowa

These people made a 3d printer that uses legos:
<a href="http://battlebricks.com/makerlegobot/" target="_blank">http://battlebricks.com/makerlegobot/</a>

Drfuzzy

<a href="http://hackaday.com/" target="_blank">http://hackaday.com/</a>

tons of this stuff here

Confused

I was a at a web development conference talking to a guy who works for a Canadian consulting company, who said they have moved the the point that they just link their 3d printers direct to parts documentation at some of their client sites. That means if you make a change to what the part looks like in the shipping manual it automatically updates on the assembly line. It was amazing.

Not directly related but you know, put that on your to do list, on your printer

Mr_Headcrab

I suddenly want one of these as my Armoury...

Or it's cousin, the Makerbot.


The Reprap, and the makerbot, both use what can be described as a computer controlled Gluegun to make it's prints, although the plastic used is basically the same as legos, generally ABS, although i have seen PLA used as well. You can get a better print if you reduce the Z depth by .5 mm , it "squishes" the layers tighter so there's less air spaces. Of course, my experience with a Mendel is way less than your own, have fun making stuff

X_Stickman

A printer that can print itself? A <i>self replicating machine?!?!?!</i>

You <i>fools!</i> <a href="http://en.wikipedia.org/wiki/Grey_goo" target="_blank">You foolish fools!</a>

Mr_Headcrab

Update, thanks to this thread, i shelled out the money for a a Thing-o-matic.

If only to watch X_stickman squirm

Scythe

Riiiissseee! From the deeps!

Here's the model:

<img src="http://www.tjhowse.com/hackerspace/openjoy/gimbal_assembled.png" border="0" class="linked-image" />

And here's the printed parts:

<img src="http://www.tjhowse.com/hackerspace/openjoy/gimbal_mk1/1.jpg" border="0" class="linked-image" />
<img src="http://www.tjhowse.com/hackerspace/openjoy/gimbal_mk1/2.jpg" border="0" class="linked-image" />
<img src="http://www.tjhowse.com/hackerspace/openjoy/gimbal_mk1/3.jpg" border="0" class="linked-image" />
<img src="http://www.tjhowse.com/hackerspace/openjoy/gimbal_mk1/4.jpg" border="0" class="linked-image" />

I'm building a flightsim joystick out of printed parts and 608 skate bearings. This is the gimbal mechanism.

I've designed and printed the POV hats, but they're pretty rough at the moment.

--Scythe--

lolfighter

You should use thumbnails for pictures that big.

rockli

crazy boy ,crazy experience,but i like you ,like your team !
I want know how about the structure inside it if it is solid ?i mean you can save raw material or strong it by optimize the structure inside of it .
just like what optimize said ,this technique can be used widely at make special parts and moulds !

oh, i love it so much

Scythe

<img src="http://imgs.xkcd.com/comics/constructive.png" border="0" class="linked-image" />

--Scythe--

Context: He had advertisements in his sig.

Kouji_San

This guy might build his own some day... But his robots obviously are going to be way more awesome, did he just mention he wants to build his own factory, to be able to make things that are too awesome to make by normal toymakers. Mr. Mantzel FTW :P
<center><object width="450" height="356"><param name="movie" value="http://www.youtube.com/v/NLTl9mJYYqI"></param><embed src="http://www.youtube.com/v/NLTl9mJYYqI" type="application/x-shockwave-flash" width="450" height="356"></embed></object></center>
<div align='center'><a href="http://www.youtube.com/watch?v=NLTl9mJYYqI" target="_blank">http://www.youtube.com/watch?v=NLTl9mJYYqI</a></div>

Mr_Headcrab

<img src="http://blackmage.org/crabby/photos/ToM/ToM.jpg" border="0" class="linked-image" />

Not done yet, but thanks to Scythe, this seems like an interesting business venture. Thanks again!

Scythe

That's one stylish-lookin' printer you've got yourself there. If you have any hassles, let me know.

--Scythe--

Mr_Headcrab

Thanks!, I'll be sure to spam the crap out of you for help when the time arises

When my new Y pulley gets here, we're back in business. I can't believe that i broke it bare handed. And my Thing-o-matic kit doesn't hold a candle to your glorious Mendel, you have self replication, i have.... the ability to fix body panels with Elmer's Glue.

Scythe

So I've printed about 1/3 of the printable parts, ordered the non-printable parts, and etched/soldered up the electronics for my own mendel. The parts should arrive in a few days. Soon I'll be printin' all kinds of grubbins from the comfort of my own home.

--Scythe--

Scythe

<center><object width="450" height="356"><param name="movie" value="http://www.youtube.com/v/o7tEuBycyr4"></param><embed src="http://www.youtube.com/v/o7tEuBycyr4" type="application/x-shockwave-flash" width="450" height="356"></embed></object></center>

My order from mendel-parts.com has arrived! Joy!

I've assembled the x axis, and printed about 3/4 of the parts. Getting close now.

--Scythe--

Scythe

My printer prints! Zomg!

If you're interested in the process of building it, watch this video.

<center><object width="450" height="356"><param name="movie" value="http://www.youtube.com/v/iEe1mODgp74"></param><embed src="http://www.youtube.com/v/iEe1mODgp74" type="application/x-shockwave-flash" width="450" height="356"></embed></object></center>

If you just want to see it printing, and a finished product, watch these two:

<center><object width="450" height="356"><param name="movie" value="http://www.youtube.com/v/d0O56GCNN9o"></param><embed src="http://www.youtube.com/v/d0O56GCNN9o" type="application/x-shockwave-flash" width="450" height="356"></embed></object></center>

<center><object width="450" height="356"><param name="movie" value="http://www.youtube.com/v/ykV610E0mOg"></param><embed src="http://www.youtube.com/v/ykV610E0mOg" type="application/x-shockwave-flash" width="450" height="356"></embed></object></center>

--Scythe--

Zaggy

So, when can we expect the NS2 models to be printed? :D

Scythe

As soon as someone works out how to convert an NS2 model to an .stl.

--Scythe--

Mr_Headcrab

ns1 models conversion is REALLY convoluted. I use sketchup but in order to convert a .smd into an .stl, you fist got to convert it to a .obj in blender, then import it into sketchup, then the delicious task of cutting it up, scaling it down, and setting it so it will lay flat on the build surface.

On a related note, anyone seen REDDmonkey recently?

Scythe

So I've got my 3D printer humming along pretty well now. The print quality is a bajillion times better than it was, and I haven't had to meddle with it for a couple months.

My latest big project was a 3D printable wifi remotely operated tank, with an independent pan-tilt camera: <a href="http://www.thingiverse.com/thing:13496" target="_blank">http://www.thingiverse.com/thing:13496</a>

<img src="http://thingiverse-production.s3.amazonaws.com/renders/82/28/b9/c2/9d/overall_display_medium.jpg" border="0" class="linked-image" />

I also recently sent Zaggy something. It was pretty awesome too.

:>

--Scythe--

Align

Which parts of a tank did you say you printed?

lolfighter

My guess is the blue parts.