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

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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 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

Using Every Last Drop

IMG_20180917_Webcam 3D Print Mount

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

IMG_20180917_Webcam 3D Print Mount

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.

#3DBenchy, the Most Downloaded 3D Print

20180914_3DBenchy

If you are involved in 3D printing there’s no doubt you’ve at least heard of #3DBenchy, if not printed one, or two, or even more. What is #3DBenchy? Well, it’s a tug boat of course! But more than that, #3DBenchy has become like the “Hello World!” from coding, the go to 3D model to test out a new printer or setting. Why a tug boat? That’s a very good question, and the only real explanation is that it includes a number of features that challenge a printer including overhangs (e.g. roof) and a variety of angled surfaces. Also, it’s a little more interesting than a basic calibration cube or set of test prints.

#3DBenchy was developed by a company called Creative Tools, initially as an in-house calibration test for their own printers. On April 9th 2015, Creative Tools uploaded the design to Thingiverse for anyone to download for free, and the rest, as they say, is history. Since then the file has been downloaded over 600,000 times from Thingiverse alone, and can be found on pretty much any other 3D file sharing website. #3DBenchy even has its own website, Instagram profile, and Twitter account – talk about a famous 3D print!

I’ve never seen any need to jump on board the #3DBenchy bandwagon, however, I was recently writing up some research that required me to photograph a #3DBenchy, and I’m always up for an excuse to print something new. So here we are, #3DBenchy in hand, and given I used some relatively fast settings to get it printed in about 1 hour, I think the result is quite good. This one is the original #3DBenchy at full scale, printed without support. And of course my photos have been fed back onto Thingiverse as one of the 2788 makes of #3DBenchy, and one of 2961 posts on Instagram… and counting. Vive la révolution!

– Posted by James Novak

Yes I Wrap, Don’t You?

20180831_3D Print Vase Wrap String

One of the common features of desktop 3D printing is the sharp, hard feel of plastic with that scratchy horizontal layered surface finish. Sure plastic has many benefits, but when you handle 3D prints all day long you sometimes forget that there are other textures in the world that are soft, delicate, pleasurable to touch. Enter the wrap, an experiment that softens those 3D prints in a crafty, hand-finished way.

For this project I downloaded the Customizable Twisted Polygon Vase from Thingiverse, which you will notice when you download is a solid block. This print takes advantage of a feature known as “vase mode” in many slicing programs, although if like me you are using Cura it’s called “Spiralize,” and you will need to activate it in your settings in order to have it available in your main screen settings. Basically the idea is that you can load any solid 3D model and automatically turn it into a vase-like shape i.e. a base and an outside wall without any interior or top surface. The outer wall is a single perimeter, which the printer continually extrudes in a spiralling/helical fashion as it works its way up the vertical height of your object. So no need to use a “shell” command in your 3D CAD modelling software, you can design a solid block and let the slicing software automatically create a single perimeter based on the extruder settings of any FDM 3D printer. A fun project in itself.

Phase 2 of the project was to use some wool yarn to wrap the exterior. What’s interesting about this process is that the layered surface finish of the 3D print actually helps hold the yarn/string in place, stopping it from slipping down the vase and helping align each rotation of the yarn. A relaxing project while you’re sitting in front of the TV or Netflix! The yarn I used was very fine so took quite a while, however you could easily use a thicker yarn to reduce the amount of effort to achieve a similar result. The result is really interesting; it keeps the layered appearance of a 3D print, yet is soft to the touch and provides a unique finish to the vase. Something you could easily customise with colours and different types of yarn materials. Ultimately, it creates an interesting combination of a highly digital process with a more craft-based process and material… Something worth a bit more experimentation I think.

If you give it a go, please share a photo with me, I’d be interested to see your results!

– Posted by James Novak

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