Giant 3D Printed SUP Fin

20170511_3D SUP Fin

Behind the scenes I’ve been working on a Stand Up Paddle (SUP) fin project for quite a while now, 3D printing many prototypes, and more often than not, failing! There is more to this project than meets the eye, but for now the details are under wraps. However I thought it might be interesting to share some of the 3D prints in case anyone feels inspired to give it a go themselves.

The design pictured above is the first one that worked successfully without breaking or having other technical issues. Printed in 4 pieces on my Cocoon Create due to the size, it required a bit of gluing, and as you can see from the pink highlight, a bit of gap filling with a 3Doodler Pen (if you want to know more about using a 3D printing pen as a gap filler, check out one of my previous posts all about it). As a result the fin is about 400mm long, huge compared to the fin that came with the board (which for any SUP fans out there is a Slingshot G-Whiz 9’4″)

20170511_3D SUP Fin

These images show some of the breakages I’ve had due to layer delamination – unfortunately the optimal way to print the 4 pieces in terms of minimising support material and warping is vertical, however the optimal orientation for strength is laying down on the flat sides (similar to the image on the right). A bit of an oversight on my part I’ll admit, however I was genuinely surprised how much force the flat water put on the fin. Another issue may be the minimal infill, which was also beefed up in my later prints to add internal strength. There is always a delicate balance between print orientation, layer strength and infill in 3D printing, to name just a few!

The main thing is that the fin prototype now works, and I may have a more advanced version being printed using Selective Laser Sintering (SLS) as I write this… If you keep an eye on my blog by subscribing below, you may just get to see where this project is going 🙂

– Posted by James Novak

Lucky Bamboo, Lucky 3D Printing

20170627_3D Print Bamboo

My desk is loaded with 3D prints, I’m surrounded by plastic! To even things out a bit I’ve added some greenery in the form of bamboo. The great thing is that it can grow in water, no need for messy soil, and it doesn’t need much light (hopefully the glowing of my computer screen is plenty!)

However the pot I have for it came with a plastic insert (black) designed for soil. It only fits in one way, being tapered, so I couldn’t just flip it upside down and drill a hole to support the bamboo. Of course, that’s just another excuse to design something new for 3D printing!

The white part in the photos above is the simple part I designed, basically the same dimensions as the original black insert but reversed with an open bottom, and a hole to allow the bamboo to fit through, including its roots. This sits down loosely inside the plant pot, and then 2 smaller inserts slot in around the bamboo when it’s inserted to hold it nice and vertical (right image). All printed without support material on my Cocoon Create, now with the Micro Swiss upgraded hotend (which seems to be working very well).

It’s probably not the sort of design worth sharing on 3D file websites given it is very specific to this plant pot, but if for some reason you want this file just leave me a comment and I’ll email it to you.

– Posted by James Novak

Mashup-Yoda – Download For Free

Yoda Header

Recently I wrote a step-by-step tutorial for my friends at Pinshape about how you can use free software (Meshmixer) to combine downloaded STL files into your own unique design – this is called a mashup, or a remix. The tutorial is nice and easy to follow, and was just the start of my plan to create some really interesting designs in a series of mashups. You can find a full video tutorial and links to the written tutorial in my previous post.

Finally I’ve found some time to create mashup number 2, Mashup-Yoda! This design has taken a lot more time to create in Meshmixer, along with learning some of the more advanced tools and plenty of trial-and-error along the way. However it is based on a similar idea as the Mashup-Rex from the tutorial, combining a skeleton element with an external skin to give a cutaway effect to the creature. However, what might Yoda’s skeleton look like?

Yoda's_death

As you (hopefully) know from the film Return of the Jedi, Yoda’s body vanishes as he becomes one with the force in his death, so there is no way to know. But upon finding the Voronoi Yoda model by Dizingof on Thingiverse, it seemed like an interesting concept for this powerful Jedi, perhaps a more organic internal skeleton that was formed by the Midi-chlorians (some real Star Wars nerd talk!) that gave Yoda his power.

Nerd talk aside, as much as anything the Voronoi Yoda just seemed like a cool model that would be fun to combine with a realistic bust of Yoda, also available freely on Thingiverse. The 2 models are a great fit, with the main challenge being the slicing and dicing of the geometry in Meshmixer to create this organic looking, almost cyborg-like Yoda mashup. Mostly this has been achieved using the Sculpt tools and the Select tool to remove sections of the models and re-shape them to look like they were designed this way from the beginning.

20170625_Mashup-Yoda

I’ll admit that I did have some problems combining the 2 models into a single STL file right at the end in Meshmixer, probably due to the weird intersections between the models where I had pushed and pulled surfaces too far into a non-manifold object. I also ended up with a file size of about 87MB, a bit ridiculous for sharing online, and the normal reduction techniques in Meshmixer were just destroying the quality of the surfaces. So I ended up bringing the large STL file into Rhinoceros, reducing the mesh by about 75%, exporting as a STL, importing back into Meshmixer, using the Inspector tool to repair any little remaining errors automatically, and finally exporting a clean, 3D printable STL file. That’s a mouthful!

Now that the hard work’s been done, I’d love you to have this model for free so you can print it out, or even get crazy and try remixing my remix using some of the techniques shown in my Pinshape tutorial! I’ve uploaded it to my favourite 3D file sharing websites Pinshape, Thingiverse, 3D File Market and Cults. Choose your website, 3D print and share some photos 🙂

May the force be with you

– Posted by James Novak

Vote Now – Formlabs 3D Design Awards

2017 Formlabs 3D Design Awards

This morning I’ve woken to some exciting news – 3 of my products, which have been featured right here on my blog, have been announced as finalists in 3 separate categories of this years Formlabs 3D Design Awards!!

If you’ve enjoyed following my 3D printing projects, I would love it if you could take 30 seconds to follow this link to the voting page, click on the big green START button, and select my 3 designs. Winners are determined by quantity of votes from the public, so get voting now! The 3 products are:

  1. Art and Design Category: X-Men Cyclops Goggles (pictured above)
  2. Engineering Category: Garmin Virb X Floaty Mount
  3. Education Category: Pine 64 Snap Enclosure

Make sure you take some time to check out the other designs as well – there is some stiff competition in each category, and some great models to download and 3D print.

Thanks in advance for your support 🙂

– Posted by James Novak

InMoov Custom Mobile App

It’s been a while since posting about the InMoov robot hand I started building last year. Previously I had everything assembled and was using some direct controls in Grasshopper (plugin for Rhino) to test and tweak the movements of the fingers and wrist (click here to see the last video). That was fun, but not as fun as being able to control the fingers wirelessly from across the room!

Using MIT App Inventor, I’ve created a very basic mobile app that now allows the fingers and wrist to be controlled on my phone using a Bluetooth connection to the Arduino board. It’s nothing fancy right now, just some simple sliders that control the servos, but now that the basics are working some more automated movements could be set up eg. by using the built-in sensors of the phone, movements could be controlled by simply tilting the phone.

20161203_InMoov Display

In order to display the working InMoov hand at the CreateWorld Conference last year, I  also built a display box from plywood since the arm is not really attached to anything and there are a lot of electronics dangling around that are a bit too messy for display. It actually makes moving the hand around and working on it quite a bit easier now since it’s raised up as well. If I had files for this case I would share them, but I went old-school for this one and just created it freehand with a jigsaw – I’m not completely reliant on digital manufacturing (yet!). Inside the box on the right are all the messy electronics, and a hole for the Arduino USB cable to reach through to connect to computer when needed.

I’ve also 3D printed a stamp with my name and the edditive logo to “tag” this project. Using 3D printing to make custom stamps is something I wrote about in one of my first ever blog posts, click here to take a trip back in time. It’s always the little details that bring a project to life for me.

– Posted by James Novak

The Meshmixer Mashup: Mashup-Rex!

Tutorial Meshmixer Mashup

The mashup is a favourite technique in the music world that combines two or more songs together into a single song. They might be from completely different eras or genres and when cleverly mashed together, they create a new smash hit. But did you know that creating a 3D printable mashup is just as easy as creating a musical one? Take a bit of File A, mix it with File B, and you now have your own creative design.

Over the last few weeks I’ve been putting together a new tutorial for my friends at Pinshape, which includes my first video tutorial as well as the usual step-by-step process to follow along with. Click here to learn how to mashup STL files in only 10 easy steps using the freely available software Autodesk Meshmixer.

The mashup is often called a Remix in the 3D printing world, and is a great way to build upon other designs and add your own creative touch, or re-purpose a design for a new application. The video tutorial is a real-time look at the process, which with a bit of practice, will have you remixing new designs in a matter of minutes. If you want to follow along, you just need to install Meshmixer on your computer, and download the 2 T-Rex files used in this tutorial which are free on Pinshape:

  1. Low Poly T-Rex by steven_dakh
  2. The T-Rex Skull by harry (we are only using the head piece, not the jaw)

Mashup-Rex

Alongside the tutorial is my latest design, the Mashup-Rex. I have made this available for free on Pinshape, just click here to download the file. Maybe you you will create your own remix of my remix? If you do, or you just 3D print the Mashup-Rex for yourself, please share it on Pinshape to add to the community and see how far the design can go! In the version pictured above I simply used a coffee stain to “age” the skull, similar to my previous print of the Star Wars Deathtrooper. I’m enjoying this simple technique at the moment, although you may like to use a 2-tone print, or go all out with some painted effects.

Happy mixing!

– Posted by James Novak

Moreton Technology Alliance

2017 Moreton Technology Alliance

Last week I teamed up with fellow Advance Queensland Digital Champion  (AQDC) and resident of Moreton Bay, Kate vanderVoort, to discuss the latest digital trends in social media and 3D printing with local businesses in our area. This was hosted by the newly formed Moreton Technology Alliance (MTA), a group of local business owners who are passionate about the region and driving innovation here.

Having been an AQDC for a couple of years now, it was great to team up with newbie to the program Kate, and deliver our insights into what may at first seem like 2 different topics. Kate began by sharing her experience with helping businesses engage with their customers through social media, and how businesses that do this well are finding that their communities of followers begin to act as customer service agents and brand ambassadors, solving fellow customer problems using the immediacy of social media. In Kate’s words, it’s a good problem to have – until your employees start feeling like their jobs are in jeopardy!

This idea of building online communities linked well to my later discussion around Intellectual Property (IP) and how online communities of designers like myself are tapping into the growing libraries of files on websites like Thingiverse and Pinshape to replace broken products, upgrade them, or modify them to perform new functions, sharing our designs for free, or for small payments just like buying a song on iTunes.

20170420_3D Print GoPro Mount

I used the example of GoPro mounts which retail at $29AUD for a pack of 6 genuine mounts, or I can 3D print 6 for $1 in material cost (pictured above from Thingiverse). Sure it’s not quite as perfectly fitting, and the material might break, but I could print 174 mounts for the same cost as 6 genuine mounts – essentially a lifetime supply from my own desktop factory. And this is just from a $400 machine, what if I have a better machine or material?

How do businesses deal with this? Will they be forever chasing people around the world with cease and desist letters (lawyers would be rubbing their hands together!)? Or will businesses shift their thinking and embrace this change, in the same way Hasbro’s My Little Pony has become an online community through Shapeways, where children and adults alike are encouraged to design and sell their own My Little Pony creations?

I certainly don’t profess to have the answers (in short I’m not a big believer of IP even without the 3D printing aspect), however the point of this example, along with examples of projects happening from a variety of industries embracing 3D printing, was to inspire the audience at this MTA event, and encourage further discussion. Which I believe it did given the questions from members afterwards, and realisation that this technology really will affect anyone developing physical products in some way or another.

We also discussed opportunities for businesses to collaborate with universities in order to develop research programs into technologies like 3D printing, with the Australian Government recently changing funding models for universities to emphasise greater links with industry, and grants announced for SME’s to fund innovation in partnership with universities and researchers. Follow the links to find out more information.

Thanks to MTA for inviting me to speak, I hope to be fielding a few questions in the near future from businesses who have been inspired to take the 3D printing plunge!

– Posted by James Novak

Star Wars Death Trooper

20170415_3D Stormtrooper

Sometimes you just see a 3D print and think OMG, I NEED THIS!

Enter the Star Wars Death Trooper model by Paul Braddock, available for free on Pinshape. Having repaired my Cocoon Create 3D printer (again!) in my previous blog post, and also upgraded my version of Cura (losing all of my print settings refined over the last year), this was a great model to iron out the kinks and get back to normality – I hate being without a working 3D printer.

From a technical standpoint my print isn’t perfect with the wall thickness far too thin, leaving some holes and messy details (eg. if you look closely at the eye socket of the skull). My new Cura settings still need some tweaks. However given all the hurdles, it’s still a pretty damn cool print that is really brought to life by the addition of a bit of black paint, and a simple coffee stain for the skull. I recommend checking out the original by Paul to see all the details of the design that aren’t captured well in my print, he’s done a brilliant job of finishing his print to give it an aged bronze look that shows every little scar and crack of the smashed Stormtrooper helmet.

If you want to make one for yourself, don’t forget to upload a photo of your 3D print to Pinshape by May 12th – there is a competition to win 1 of 40 rolls of filament (ABS or PLA) or some Resin if you use an SLA printer. You get an entry for every 3D print you upload of anything on the website!

– Posted by James Novak

Is That A Clogged Nozzle, or…

20170413_3D Nozzle Clog

No it’s just a clogged 3D printer nozzle, thanks for asking!

2017 seems to be my year for repairs on the Cocoon Create 3D printer, it was only a few months ago I wrote a big post about repairing and replacing the PTFE tube after it got seriously clogged. I did some research and found out exactly what the tube is for, and bought a roll of spare tube for future repairs (click here to read more).

Lucky I did! This seems to be the same sort of problem, however instead of the PTFE tube just getting clogged, when I opened up the nozzle the tube had become melted and broke off inside, completely stuck as you can see in the photo. I wonder if the spare PTFE tube I had installed was made from dodgy materials, allowing it to melt? Or maybe the ABS filament had just found a way around the outside of the tube and caused it to clog. Either way it’s getting a bit frustrating to have the same issue.

Luckily this wasn’t too difficult to fix (although I did jump straight on Ebay and buy a couple of spare brass nozzles – just search for RepRap MK10 0.4mm nozzle since the Cocoon Create is based on the RepRap Prusa i3). Using a drill and holding the nozzle with some pliers, I gradually worked my way up from a 2mm to 4mm diameter, clearing out the clogged material. 4mm is almost exactly the same as the internal nozzle diameter, so it cleared everything out nicely.

With some new PTFE tube installed, I’m back up and running again and the first print is coming out nicely (stay tuned to see what it is). Let’s see how long it lasts this time…

– Posted by James Novak