Hex Business Card Holder Tiles

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A new office and a new excuse to design and 3D print something! Like many people I end up with piles of business cards that I don’t know what to do with. They clutter my desk, get lost, and ultimately end up in the bin. Sure, there are loads of fancy solutions at stationery stores, and plenty of apps to digitise them, but where’s the fun in that?

Now that I have pinboards wrapping my desk I decided to design a simple, easy to 3D print hexagon business card holder that could be pinned up out of the way. After all, everyone loves hexagons right? While the design is extremely simple (a few extrudes and cuts in Fusion 360), the trick was to model it in a way that would allow it to be 3D printed without any support material – so, as you can see from the layers in the photos, they are (perhaps counter-intuitively) printed in the same orientation they are used. This was an important thing to consider during the design process, with no horizontal beams and all angles >30° from horizontal, and is an important part of what’s known as Design for Additive Manufacturing (DfAM).

There is a small hole and recess to fit a thumb tack, and you can 3D print as many as you need. As usual you can freely download and print this design for yourself from Thingiverse, Pinshape, MyMiniFactory or Cults, and I’d love to see photos of how big you can make your Hex Business Card wall!

Happy printing 🙂

– Posted by James Novak

 

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3D Printing Pop Culture & Viral Objects

20190508 Pop Culture 3D Print

As regular readers of this blog will know, I’ve been involved with 3D printing, making, education and various online communities for a while now. Which is why it’s very exciting to share my latest piece of writing, a book chapter titled “The Popular Culture of 3D Printing: When the Digital Gets Physical” which I wrote with former colleague and fellow maker Paul Bardini from Griffith University.

As the name suggests, the chapter looks at the popular cultural context of 3D printing, rather than the more technical aspects featured in most academic writing. As makers, we are both really interested in the growth of 3D printing and spread of 3D printing files on platforms like Thingiverse, MyMiniFactory and others, so we got a bit scientific and collected some data. The results are very interesting!

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Firstly, one of the things we did was collect the total number of files available from a range of 3D printing file repositories, as well as other more general 3D file repositories. Above is the data we collected (on 26th August 2018) which clearly shows Thingiverse to be the largest specific 3D printing file website. This is no surprise given that the website began in 2008, well before most competitors, building a network effect that still seems to be going strong despite some of the most recent challenges Thingiverse has been experiencing. However, there are plenty of other much larger libraries of CAD files that could be searched for 3D printing files, and even though some will be specific to certain CAD software, there’s always a way to make these 3D printable.

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Given the size of Thingiverse, we then looked at the most popular designs on the platform, collecting data (you will have to check out the full chapter for this!), and then calculated the average downloads per day for these designs. The graph above shows this data against the date the design was uploaded to the platform. Some of the names you may recognise: #3DBenchy, Baby Groot, the XYZ 20mm Calibration Cube and the Xbox One controller mini wheel. But what does it all mean?

Well, the short story is that objects uploaded to Thingiverse today will be downloaded in higher volumes per day than objects uploaded earlier in Thingiverse’s history. The trend line is increasing, matching the growth of 3D printer ownership; more people are downloading more things, with the Xbox One controller mini wheel recording 700 downloads per day when it was newly released. However, #3DBenchy is by far the most downloaded design of all time, right now having been downloaded over 900,000 times on Thingiverse alone, as well as being available on almost every other 3D file platform. This has lead to our classification of it as a “viral object.” Similar to viral videos and viral media campaigns, a viral object extends these concepts into the physical world through 3D printing, being first spread rapidly through online file sharing communities, then turned into physical objects in their thousands despite each being made in a different location, by a different machine.

This raises some interesting questions:  A viral video or piece of advertising made up of digital bits can easily be deleted, but how do you delete a viral object made up of physical atoms? Simply discarding 3D prints into landfill is unsustainable, and new solutions are necessary that make recycling of 3D prints affordable and accessible to the masses. It is also worth looking at the quantities an object like #3DBenchy is being downloaded and 3D printed, which is clearly in a magnitude similar to injection moulding and the mass production paradigm that 3D printing is supposed to disrupt. While it’s useful to have an object to calibrate and compare 3D printers, it’s also interesting to see that people still want to print and own the same object, rather than being truly individual.

The trend for viral objects is certainly one to watch, and the chapter provides a detailed analysis of this and other emerging trends related to 3D printing and pop culture. If you’re interested in reading the chapter, you may use my author discount code “IGI40” to get a 40% discount, or if you’re at a university you may find you already have access through your library subscriptions. Paul and myself certainly welcome your feedback and thoughts 🙂

– Posted by James Novak

Shim the 3D printed shim

IMG_20190226_3D Print Shim Doorstop

We’ve all experienced that wobbly table at a cafe and struggled to wedge coasters and napkins under the legs to balance it out. This is where you need a shim, a small wedge that can fill the gap and ensure your drinks don’t go flying. Shim is also fun to say, quick to 3D print, and a good test of your print settings due to the top surface exhibiting the stair-stepped effect.

There are many designs available on popular 3D printing file websites, but I just wanted one that was a useful size (easy to carry with you in a small bag) and that said what it was. So here it is, Shim the shim! You can download it for free on Thingiverse, Pinshape, Cults or MyMiniFactory. Alternatively you can follow the basic outline of the design process below to make your own from scratch in your favourite CAD software. It’s similar to some of my previous designs including an “edditive” desk logo which might give you some inspiration for different ways to use text in 3D.

IMG_20190226_Solidworks TextShim was designed in Solidworks by using the text tool on the top sketch plane. The key is to squish all of the text together so that the letters intersect, meaning they will 3D print together as a single object (in Solidworks you can simply change the spacing of text within the text tool). The text was then extruded 10mm, creating solid geometry. All you need to do to create the wedge shape is then slice a triangular portion off the top, which in Solidworks uses the extruded cut tool. Save to STL and 3D print, it couldn’t be much simpler!

This is a nice quick 3D print and could easily be used as a keyring or give-away item, especially if you design your own. Enjoy, share and print!

– Posted by James Novak

3D Scanning Natural Forms

IMG_20190117_3D Scan EinScan Pro

This is a post about my new favourite toy – the EinScan Pro 2X Plus 3D scanner from Shining 3D. Why? Because it allows you to turn any object into a 3D model! And I can tell you upfront, it works REALLY well!

This is not the first 3D scanner from Shining 3D, which is a good sign that both their hardware and software has had time to mature. The EinScan Pro 2X Plus is brand new to the market, which means there are not many reviews at the time I’m writing, although you can find a brief overview from 3D Scan Expert and will no doubt see a full review from him in the near future. I’m not a 3D scanning expert, so am not going to dive into all the details here. I have used several scanners in the past and written a few posts, but this is the first that I have full access and control over and am currently using on a daily basis.

Enough with the introductions. One of my first experiments has been to 3D scan some challenging organic forms, including some shells which I picked up from the beach. The top photo shows one of these shells being scanned (we have the “Industrial Pack” turntable and “Colour Pack” upgrades for the scanner). The process is straight forward in the accompanying EXScan Pro software – a few basic settings about the detail you’d like to capture and press go. The turntable and scanner do the rest, and you can see the points being captured in real-time on screen. There is a bit of cleanup after the first scan to remove any points that aren’t needed (e.g. you can see in the photo some points around the perimeter where the scanner picked up an edge of the turntable), at which point you have your first scan.

This could be all the detail you need depending on your application; however, all you have is an outside collection of points, with no detail about the inside of the shell. So I then flipped the shell over and performed a second scan. The only difference from the previous step is that now there are 2 scans. Amazingly the software is proving quite intelligent at automatically aligning multiple scans, finding common points and bringing them all together. This doesn’t always work, and there is an option to manually align 2 scans by selecting 3 common points in each. I must admit the interface for this process is quite painful to use at the moment, so it’s always great when the software automatically does this. Overall the software is very basic, you really don’t have a lot of control – which can be both a blessing and a curse. You certainly can’t perform any sort of editing actions other than selecting and deleting points.

The final step is to turn all of the points (aka. point cloud) into a mesh suitable for 3D CAD software, or 3D printing. There is an option to create a watertight mesh, letting the software automatically fill any holes in the model. For this shell scan I only had very minor gaps which were nicely cleaned up and blended into the mesh. However, I have found with some other scans that if holes are quite large, or there are some messy overlaps in scan data, the software will produce some weird results – best to keep scanning to capture as much data as possible before creating a mesh, once you get to this step there is no turning back.

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Best of all, being a watertight mesh, the file can be immediately used for 3D printing. But why simply replicate a shell? I always see large shells as decorator items in stores retailing for hundreds of dollars – and now I can 3D print them for a fraction of the price. This one was scaled up 500% and printed on a Wanhao Duplicator D9/500 – which is still working somewhat consistently after my previous post and firmware upgrades. I decided to print it in an upright orientation so that the 0.5mm layers are similar to the layers naturally occurring in the shell. Even though the print quality is still quite rough, I think this only adds to the natural effect.

The shell has been saved as a .obj file, meaning that it has all the colour information along with the geometry that would normally be a .stl file. I have shared this on Sketchfab so that you can have a closer look at the mesh in 3D using the above viewer. I think it’s a really great result, and hopefully you can see why I have called this my new favourite toy. It really does open up new opportunities (perhaps you’ve already seen some new experiments if you follow me on Instagram). Stay tuned, I’m sure there’ll be plenty more posts that involve 3D scanning and 3D printing in the future.

– Posted by James Novak

3D Printed Chainmail: Size XL

20181030_3D Print Chainmail

If you’re into 3D printing like me, chances are you’ve already 3D printed chainmail and been excited by the ability to produce something that is made of multiple parts already assembled and ready to go. If you’re new to 3D printing, what you might not realise is that because you are printing objects in small layer increments, you can print these layers in such a way that different pieces become trapped within each other as the print progresses, permanently assembling them together. This means that something like chainmail, which has been hand assembled for thousands of years one link at a time, can now be printed with all the links in place.

One of the most popular examples in recent years has been from well known designer Agustin Flowalistik, whose unique design of chainmail has been downloaded over 100k times already on Thingiverse! Click here to download the file for yourself and add to this growing number. After one of my previous posts about the new Wanhao Duplicator D9/500 printer, I wanted to see how it would handle the intricate geometry, however, at 200% the scale. Go big or go home!

Well, as you can see from the photos it worked quite nicely. With the large 0.8mm nozzle the layers certainly look rough and messy – this print isn’t going to win any awards for being pretty. But it worked, and on this sketchy 3D printer that’s the most important thing at the moment. One of the nicest things was peeling it off the magnetic flexible build plate of the D9, which you can see in the first picture above – no hacking away with a spatula which is one of the positives of the printer. The links freely move and because of the large size, the chainmail has quite an industrial feel about it. Very satisfying.

So I think I can chalk this one up as a win on the Wanhao D9, which I think brings my score up to about 2 wins, and too many failures to count… Not great but after a firmware update I hope there will be some more wins to come.

– Posted by James Novak

3D Printing Education Book

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As many readers will know, this blog came about when I started my post-graduate studies at university focusing on 3D printing. My knowledge allowed me to get into lecturing, and part of this role has allowed me to run workshops for the community, including school teachers, secondary students, and the broader public. It turns out these experiences have taught me a thing or two about running 3D printing workshops in short time-frames, often with people who have never seen a 3D printer in action, and has lead to me publishing a chapter in a book detailing how I organise a one-day 3D printing workshop.

190112 3d print education book

The book is called Interdisciplinary and International Perspectives on 3D Printing in Education, and includes 14 chapters from leaders around the world on the topic of 3D printing in education. My particular chapter is called Re-Educating the Educators: Collaborative 3D Printing Education, and calls attention to some of the many real challenges that plague teachers who are attempting to adopt 3D printing in the classroom. The chapter starts with a summary of how Australian schools are adopting the technology, and moves on to new research and peer-reviewed literature about how short, intensive courses are helpful in offering teachers meaningful training in regards to 3D printing. The later section of the chapter provides the organisational structure and hands-on activities I use in my workshops, and is hopefully useful to many other people who are running training programs for teachers and others interested in 3D printing.

A big thank you to Sarah Saunders at 3dprint.com for writing a great article about my research which you can read here. The article provides a nice summary of the book which I hope will help it reach a wide audience, as there is not enough material available for teachers, curriculum planners and education researchers wrestling to bring 3D printing and other technologies into the classroom. This book at least goes some way to presenting the latest research ideas and data to fill this gap.

Please help spread the word to anyone who may benefit from this book on 3D printing in education, and use my 50% discount code “IGI50” to purchase the whole book, or just my chapter, at a generous discount 🙂

– Posted by James Novak

3D Printed Medal and Trophy

IMG_20181024 3D Printed Trophy Medal

As a product designer focused on 3D printing in my job at the University of Technology Sydney, it was no surprise that I found myself being asked to design some 3D printed awards for the end of year 2018 Vice-Chancellor’s Awards for Research Excellence. And while not receiving an award (yet!), I think it’s even more fun to get to be designing them – besides, now I can print them out for myself!

I was asked to design 2 different awards which you can see pictured above. The first were a set of 3 medals, and my only brief was to have them 3D printed in metal, and for them be approximately the size of previous medals given out for the awards. I based my design on a spinner concept which I’ve previously printed, with an important feature being the cone-like details which hold this assembly together when printed as a single part. There is no support material required, with one of my goals being to highlight through the design the capabilities of 3D printing in metal. For recipients, my goal was to create something playful and engaging, rather than most medals which are kept in a case and quickly forgotten. Thanks to my friend Olaf Diegel at Lund University for printing these in aluminium and sending them to us in time!

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For those familiar with metal 3D printing (Direct Metal Laser Sintering to be specific), you can probably guess there was a lot of manual post-processing of these medals to remove the base supports and polish the surfaces. Below you can see the medal as it comes out of the printer on the left (once cut from the build plate), and the final polished version on the right. All of the base support material you can see in the raw version had to be filed away while held in a vice, before going through a lengthy process of polishing. Slow, painful work, but you haven’t truly 3D printed in metal until you’ve gone through this process, it makes peeling away plastic support material from FDM prints seem like child’s play!

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The second award was a trophy which also continued with the 3D printed assembly concept. My only brief for this design was for it to be printed on our own HP Multi Jet Fusion 3D printer, which is very similar to SLS printing. Many of us have seen the “ball in a ball in a ball” type of prints which are often shown at 3D printing expos and events, and I built off this to incorporate a lattice frame to contain the balls. The basic design was done in Solidworks, however, the balls were just solid spheres at this stage. I then exported them into Meshmixer in order to apply a lattice structure to them, using 2 different geometries. All parts were then imported into Meshmixer in order to export them as a final fully assembled file ready for printing.

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A little bit of laser cutting and timber work by a colleague really helped bring the design to life, and again, the trophy encourages interaction and play. Congratulations to the winners and finalists, I hope you enjoy your awards as much as I did creating them. With any luck I might get to design them again in 2 years and bring one home myself for real! 😉

– Posted by James Novak

Using Every Last Drop

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Perhaps it’s the result of spending 10 years as a poor uni student, but I really like to use every last drop of liquids: sauce, toothpaste, shampoo and yes, deodorant. Many of the roll-on style deodorants, such as those from Nivea, have a domed lid, meaning it’s impossible to tip them upside down as liquid is running low and store them so gravity can do its thing. In my mind, this is a design flaw in the packaging (although from Nivea’s point of view, this is a great way to keep people buying more products more often).

I had originally planned to create my own design to solve this problem, however, after a quick search on Thingiverse I was pleasantly surprised to see many people had already beat me to it! There are plenty of designs to choose from, and I decided on this helix design for its interesting form. Click here to download the file for yourself from Thingiverse.

The print took just over an hour to complete, and as you can see from the pictures, it does exactly what it promises. I also streamed the 3D print on my YouTube channel, so if you like watching the grass grow, here is an hour of entertainment just for you! Make sure you subscribe if you want to be alerted of the next live 3D print 🙂

– Posted by James Novak

First 3D Print with the Wanhao Duplicator D9/500

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If you have followed my blog for any length of time, you’ve probably noticed I’m quite a big fan of the Wanhao 3D printers – they’re cheap, reliable, upgradable, and just good value for money. Even my Cocoon Create from Aldi is actually just a Wanhao in disguise! Recently Wanhao released the Duplicator D9/500, which has an incredible 500x500x500mm build volume. Yes, you read that right, those numbers are not a typo! The picture above doesn’t do it justice, this is a big unit that currently we can only store and run on the floor until we can free up a large desk. Manoeuvring this thing is definitely a 2 person job!

Before I get into the details of the machine and my first experiences, the printed vase pictured above is the first successful print, which is the Curved Honeycomb Vase (free on Thingiverse) printed at 200% scale. Printed in vase mode (aka “spiralise” in Cura) with a 0.8mm nozzle, this print took approximately 6 hours to complete. A great design in itself, and very cool at this large size.

However, it certainly hasn’t all been smooth sailing with this printer. First, there were some lengthy delays from Wanhao between when we placed the order and finally received the machine – apparently some manufacturing and quality control issues, and Wanhao may have released the machine a bit too early to market. In total we waited several months, however, they may be much faster now that issues seem to be resolved. The second big issue we faced was assembly – the supplied instructions weren’t particularly useful or even relevant, with some of the components no longer supplied with the printer – it seems that the initial release included large brackets to help stabilise the frame and some other details in the instructions, so we were left feeling like we were missing some parts. Apparently we are not, although we still haven’t figured out some of the cable management issues and have had to hack together a temporary solution for now.

Another challenge with assembly was in constructing the frame; obviously at such a large size the frame wasn’t pre-assembled like the smaller Duplicator 3, and the frame also uses extruded aluminium rather than folded sheet metal. Squaring all of these extrusions is not simple, and some initial issues when running the machine were related to having one of the vertical frame pieces lightly twisted. Some better alignment details are definitely needed.

The final issue that we’ve been experiencing is in the auto-levelling sensor, which was not installed at the correct height in the factory and required a lot of manual adjustment (we had the nozzle collide with the bed several times when first running it). However, even with this, the machine doesn’t really seem to adjust the prints for any levelling issues; our first prints across the bed revealed a number of areas where the bed was slightly warped, which were not being corrected by the auto-level feature, so we are currently manually doing adjustments for now. And we have found the central area of the bed is OK, so the vase printed really well.

So overall I would have to recommend that anyone considering this printer hold off for at least a few more months, there are just too many issues for anyone without a lot of experience calibrating 3D printers, and without the time to really get in and troubleshoot issues. Last time I searched on YouTube it seems others have also come to a similar conclusion. I think with time this will be a great 3D printer, we’re certainly going to keep learning more about it, but this seems like a case of a manufacturer rushing to market without properly testing and perfecting their equipment. Unfortunately, an all too common story in the 3D printing world.

Make sure you follow my blog and social media accounts to keep up to date with ongoing test prints and posts about the Wanhao Duplicator D9/500. And please share your own experiences in the comments section so we can all learn from each other 🙂

– Posted by James Novak

*UPDATE 14/1/2019 Recently I have updated the firmware of the printer to see if that would improve performance of the machine. I recommend this as a priority for anyone with a D9, it could fix some of the issues you may be experiencing as there are probably several different versions of firmware out there now depending when you purchased your printer. While I haven’t noticed a difference with the levelling issues, it’s always worth running the latest firmware to fix any other potential issues. This video tutorial is excellent, I followed it exactly and managed to update both the LCD display and motherboard to version 0.164(B).

For now I’ve manually adjusted the levelling sensor so that in some areas the nozzle is lower than it should be, pushing into the print surface. This makes other areas of the warped plate the correct height, and after a few layers seems to level things off and be printing OK. Not great, but working for now.

3D Printed Webcam Mount

IMG_20180917_Webcam 3D Print Mount

Whenever I travel I always have a small Guerrilla tripod to easily mount my cameras just about anywhere – the flexible arms make it perfect for wrapping around handrails or quickly levelling on uneven surfaces. Which made it my first choice when it came to mounting an old webcam so I can begin streaming my 3D prints to Youtube!

I’m seeing a lot of people like @wildrosebuilds posting awesome time-lapse videos of their 3D prints, and plenty of tutorials online showing how to build quite elaborate rigs to do so. I don’t really have time to deal with all of the video editing for each print, but the opportunity to live-stream prints directly to Youtube seems like a great way to share what I’m working on in real-time, and also allow me to monitor prints without having to physically be with the printer. However, webcams aren’t designed to mount to the typical screw mechanism used by tripods/cameras, so I had to design my own bracket to allow me to mount an old Logitech C270 HD webcam to the tripod.

The top right image shows the small slide-in clip that screws to the underside of a camera, and locks into the tripod. My first step was to reverse engineer this part with a set of calipers, modelling the geometry in Solidworks. I then added a vertical element to attach to the webcam, which has a hole on the back normally used by a bracket attaching the webcam to a computer screen. An extra lip on the front to hold the webcam in a vertical orientation, and voilà!

The blue bracket has been printed on my Wanhao Duplicator i3 Plus in PLA, and a screw I had lying around holds the webcam to the bracket. A nice little solution that should see some action very soon. Subscribe to my Youtube channel or follow me on Twitter to be alerted when I begin streaming prints, I know it can be a bit like grass growing but watching 3D prints is still addictive to me. If you’d like to download this design for yourself, you can find it on Thingiverse, Pinshape and Cults – feel free to make your own modifications as needed and share, I know the C270 is quite a popular webcam.

– Posted by James Novak

UPDATE: If you want to see my first live-stream using this webcam mount, here it is:

Check out my channel to see more, and subscribe to be alerted when I go live.