Mannequin Head Remix

3D Print Mannequin Head

Close but no cigar.

Sometimes you find something close to what you want on Thingiverse, Pinshape or other 3D printing platforms, but it’s just not quite right. Well, there is often something you can do about it, and it won’t cost a cent.

I’ve written several tutorials about using free software Meshmixer to make various modifications, for example creating a mashup of 2 different files or adding some text to a design. On this occasion I found a 3D scan of a styrofoam mannequin head on Thingiverse, which included all of the messy details you’d expect from a foam model (smaller head in the image above right). Great if you’re after realism, but not great when you want nice smooth surfaces for 3D printing. The model was also not at the correct scale, and I wanted a mannequin head to use as a model.

The scale was an easy fix, and of course could be done in your slicing software.  Cleaning up the surfaces was also quite simple using the ‘Sculpt’ tool and choosing one of the smoothing brushes. This essentially irons out all the rough details, smoothing out the model as you brush over it. A few minutes of work and a rough model is now clean and ready for 3D printing – which of course I’ve uploaded as a remix on Thingiverse so you can download it for yourself.

The above left image shows the 3D printed result from a Creality CR-10 S5, a very cheap, very large FDM machine with a build volume measuring 500x500x500mm. Obviously my settings weren’t great, the seam is in the worst possible position, and because I wanted a quick result I used only a single wall thickness and almost no infill, which split apart at the top. However, it’s fine for my purposes, and the surface quality on most of the model is fantastic.

Happy smoothing!

– Posted by James Novak

Hex Business Card Holder Tiles

IMG_20190507_Hex Business Card Holder

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

 

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 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.

3D Printed Hooks

20180521_3D Print Hook

3D printing really does solve so many problems – previously I’ve replaced a small whisk in a milk frother, produced my own kitesurfing fins, 3D printed locking mechanisms for some stand up paddles, and made numerous enclosures for Arduinos. What did we do before 3D printing?

This is yet another example of the need for a unique part – some hooks to display some work in front of my office, which could attach to some vertical plywood fins without permanent fixings like screws or staples. The plywood is 17mm thick, which was the only dimension needed to create this hook design, and I’ve modelled the arms to be a maximum of 17mm apart, with a 1º draft angle to really hold on to the plywood towards the back of the arms which are less than 17mm apart. This creates a good clamping force on the plywood. They are also designed so that they require no support material when 3D printing, making them fast and efficient to produce.

While it’s quite a unique case, I’ve decided to share the design on Thingiverse, Pinshape and Cults  in case it’s of use to anyone, or even just a good starting point for your own design. You could even try scaling them in width to fit the dimension of your vertical board. Happy printing.

– Posted by James Novak

3D Printed Assemblies

20180420_3D Print Moving Assembly

One of the most interesting features of 3D printing is that it’s possible to print multiple parts in their assembled state, reducing the need to bring together a whole range of different pieces and assemble them using screws, snaps, glue etc. While this is normally easier using the Selective Laser Sintering (SLS) process, with a bit of experience and some clever design skills, it’s possible to 3D print moving assemblies on a basic desktop FDM machine.

Pictured above are 2 objects I’ve been wanting to 3D print for a long time as great examples of what can be done with an FDM machine. The first is called an Air Spinner and is free to download from Thingiverse. Due to the tolerances and angles between each part, no support material is needed, and you can literally start spinning each of the pieces straight off the printer, functioning like a gyroscope. A nice quick print, and a great demo piece. Below is a video I found of someone printing and spinning one so you can get the full effect.

The second print pictured to the right is a Planetary Gear Keychain, also free to download from Thingiverse. This one is much more of a test of your printer’s settings, the first time I printed it all of the pieces were completely fused together and impossible to free. Even this print required a knife to separate pieces that formed part of the first layer, with the squished plastic bonding them together as my nozzle was slightly too close to the print plate. This one is remixed from another design on Thingiverse which I recommend you check out for all the instructions to help get the best result, and read how other people achieved successful prints. Here’s a short video to see the planetary gears in action

If you’re looking for some fun prints to share with people, these 2 are very much recommended and relatively quick, although I’m still a very big fan of the Kobayashi fidget cube from one of my previous posts whichis another great assembled object. If you’ve got a favourite 3D printable assembly, leave me a comment/link below and I might add it to my list of things to make!

– Posted by James Novak

Return of the Beer Bottle Lock

20170823 Beer Lock Blank

It’s been quite a few years since I first posted this design on my blog – check out where it all began here. One of the great things about sharing designs like this on file sharing websites like Thingiverse or Pinshape is that you get to see when someone enjoys your design and shares their own photos of the print, or even better, remixes it to add their own unique twist to the idea. Someone even made a video on Youtube which featured this lock 🙂

Occasionally I get requests, either on these websites, through social media, or on this blog, for me to make alterations to a design, or share the native design files for someone to more easily modify. 9 times out of 10 I’m more than happy to help. A few days ago I was contacted through Twitter to make a simple variation to my Beer Bottle Lock, removing the text on top that says “hands off my beer” to provide a blank surface for someone to more easily add their own custom text.

Given that the file is parametric in Solidworks, the alteration only took a few seconds. However rather than email the files direct, it seemed like a good opportunity to share a remix of my own design on Thingiverse, and hopefully benefit even more people. So you can now download this design for free by clicking here, just like the original.

This got me thinking about remixes, and the fact that many of my favourite 3D printing sites like Pinshape and Cults don’t really allow for remixes to be clearly linked to the original source file. I can either upload a print of a design (just photos, not a new STL file), or upload a completely new design. If I want to let people know this new design is a remix, I have to manually write this in the project description, and supply a URL to the original file as you can see on my upload of this new blank version beer bottle lock on Pinshape. On Thingiverse, you can specifically say your design is a remix of another with the click of a button, and a link is created so others can easily go to the original, and see all remixes to find the one most appropriate for them. This is a better system that ties in with the whole Creative Commons (CC) licencing used by all of these websites.

I hope some of these other file sharing websites will take up the challenge to make file attribution and remixing more transparent, it shouldn’t be left up to the user to understand the licensing options and manually enter this information. A common standard across a website, as done by Thingiverse, would really help encourage more sharing, and appropriate attribution to designers.

– 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

Enabled by 3D – Twisty Pen Grip

20160829_3D Print Pen Grip

It’s competition time at MyMiniFactory and I thought I’d use it as an excuse to spend an afternoon creating something new and simple to 3D print. The “#enabledby3d” competition brief calls for an “item that makes an everyday chore easier, or an enabling device, allowing those with disabilities greater accessibility.”

I decided to focus on something most of us take for granted – writing and drawing with a pen. If you have arthritis or some other sort of hand dexterity problems from injury or illness, picking up a cheap standard pen and using it can be frustrating, painful or even impossible. One option is to pay a lot more money for large diameter pens, or buy those slide-on grips which look ugly and draw attention to the fact that you may have grip difficulties.

So what I’ve created is a simple sheath that slides over the full length of a standard Bic pen or similar, significantly increasing the diameter of the pen and changing the geometry so that it may be more easily maneuvered. The sheath prints without needing any support material, and the cheap pen simply sides inside ready to use. What I hope is achieved by this design is something that not only enables people with hand dexterity issues, but something that is appealing to anyone – in this way the design doesn’t seem like an assistive device, but something desirable that someone might be using simply to stand out and be unique. Rotate the model around below to see all the details, particularly the spiral top.

If you like the Twisty Grip head over to the MyMiniFactory page to give it a like to increase my chances of winning the competition! Better yet, you can download this design for free and print it for yourself, or for someone you know who could benefit from it. As soon as the competition ends I’ll also post it to the other 3D printing file sites I normally use, but for now please help share this design and have some fun making it for yourself. Print in bold colours to stand out, or use different coloured materials to designate different pen colours – the choice is yours.

– Posted by James Novak

UPDATE 28/11/2016: The STL file to print this design is now also freely available on Thingiverse, Pinshape, 3D File Market and Cults. Enjoy!

Design a 3D Printed Snap-Fit Enclosure

20160623_Pine64 Enclosure

Today I’m pleased to share a tutorial that I’ve written for my new friends at Formlabs called “How to Design 3D Printed Snap Fit Enclosures.” Follow the link to read all the details, but in short, this tutorial will guide you through some of the important steps to designing your own custom enclosure suitable for 3D printing, and featuring a snap-fit detail so that you can easily open and close the enclosure without needing any tools. The tutorial is done using Solidworks, however you should be able to follow along no matter which 3D CAD software you use, even the free ones like 123D Design – the process and tips are exactly the same.

For this tutorial I used a PINE64, the famous $15 64bit computer funded on Kickstarter in 2015. The enclosure is designed to offer something unique and exciting to complement the computer, and of course take advantage of 3D printing. You can access all of the ports and features with the enclosure fitted, and there’s a great spot on top to store SD cards, USB sticks etc.

By the way, if you just want the enclosure without following the tutorial, of course I’ve uploaded the design to Pinshape, Thingiverse and Cults so you can download it and print it for yourself!

– Posted by James Novak