Category: 3d printing

Categories
3d printing CAD - Design Project

Bobble Heads

For one of the IDEA Lab events, I decided to make bobble heads of your head for my workshop. I first designed the bobble body using OnShape. This was the body that all attendees were given. To create the head, I first used the Structure Sensor Pro to scan the attendee’s head using the Structure Scanner app on an iPad to create an STL model. I sent the model to my computer and opened the STL file in Microsoft 3D Builder. I edited the model to fit the springs and connect to the body. I used the Prusa MK3S print farm to print the bodies and heads.

Equipment/Software:

  • OnShape
  • Prusa MK3S
  • Microsoft 3D Builder
  • Structure Sensor Pro
  • Structure Scanner App
  • iPad Pro 10th Generation
  • Springs

Step by Step:

  • Designed the body in OnShape
  • Create a scanned head using the iPad scanner, and sent to 3D Builder
  • Trim the head
  • Import the bobble spring attachment, which is the negative that will be subtracted from the inside of the head
  • Export the model and import the body and head into PrusaSlicer
  • Assemble the design, cut spring in half and hot glue the head to the spring, and the body to the spring

The challenging part with this project was to find a simple way to add the spoke for the spring to attach to within the head. At first, I tried to subtract a cylinder hole from the head, then add another cylinder for the spring to attach to. The issue with this was that it was difficult to get the spoke and hole to get the correct dimensions each time. I then came up with a solution by creating the negative space of the hole and spoke in CAD, and then subtract the negative from the head. This left the spoke and hole the same for each head.

Through the development of this workshop, I learned a more in-depth usage of CAD programs; problem the creation of more organic models (arms in the body). I also learned more techniques in creating 3D scans of people’s heads and further modifying them to fit our needs.

Categories
3d printing CAD - Design machine shop Programming Project

Prusa Print Farm

by Trevor Neal and Bryan Bushey

For the arrival of 12 new Prusa MK3S+ 3D printers, we needed to design a system to streamline the 3D printing process for new and returning users. We created a large shelf to store the printers by first using Fusion 360 to implement the design. We then created a scale model to accurately determine measurements. Next, we cut on the lab’s ShopBot CNC machine. Once all the pieces were cut, we assembled the shelf and sanded at 220 grits. Applying a polyurethane finishing after. When the wall was complete, we designed 3D printed filament spool rollers and pulleys to allow easy access for changing the printer’s filament. After, we designed a 3D printed sign to label our print farm, “Mount Olympus”, since we named all 12 of our printers after the 12 Greek Gods.
            Our goal with the usability of the print farm was to create an online website that allows users to select one of the lab’s Prusa 3D printers, upload their model, have it sliced using our custom profile, and automatically start the sliced print. We decided to use OctoPrint. OctoPrint is a fully open-source web server/interface to directly connect to a 3D printer. Originally, OctoPrint was designed to be installed on Raspberry Pi computers, since we had 12 printers, we wanted one system to do everything.

Equipment/Software:

  • Fusion 360
  • OnShape
  • ShopBot
  • Epilog Fusion Pro 48 Inch
  • 3mm Plywood
  • ¾ inch Plywood
  • Linux Docker
  • OctoPrint
  • Overture PLA
  • 22mm Ball Bearings

Step by Step:

  • Designed the shelf in Fusion 360 and exported the file as a DXF
  • Laser cut out a scale model on the Epilog Fusion Pro in wood, using 3mm plywood
  • Cut out the finished design on the ShopBot using ¾ inch plywood
  • Assemble the cut design (nail gun/wood glue/sanding 220 grit)
  • Finished wood with polyurethane
  • Designed spool rollers, pulleys, and wall-sign in CAD
  • 3D printed designs and installed on the shelf
  • Computer formatted to run Linux, with Docker instances installed

Using a standard desktop computer, we downloaded and installed Debian Linux to run 12 different docker instances of OctoPrint designed specifically to work for docker.

  • Create profiles for OctoPrint on each instance and install the web slicer
  • Connect printers to their respective instance
  • Create website using HTML, CSS, JavaScript

To make using the print farm easier to the end user, we created an HTML page that displayed links to each of the instances as well as a live webcam feed to visually monitor the printers.

  • Webcam installation

We wanted to also create a live webcam feed to accurately monitor on-going prints. To do so, we connected a webcam to the Linux computer and created a new docker instance for the webcam.

  • Finished

One of the main challenges with this project was to get the computer functional with 12 instances of OctoPrint using Docker. We continued to run into problems on getting the OctoPrint slicer plugin to be functional. We overcame this by researching documentation on the slicer plugin and found the correct install information for Linux. Setting up the webcam had its own issues. When creating the webcam Docker instance, the recommended image file we decided to use did not function correctly, so after trying newer images, one finally produced the results we were looking for.

During this project we learned many new and innovative ways to create a 3D printing farm. For us, we learned a lot about how docker, and its instances work on Linux systems. Creating the website allowed us to learn HTML, CSS, and JavaScript together.

Categories
3d printing CAD - Design Project textiles

Pi Holder

I designed a custom Raspberry Pi Zero holder for the desks.

Equipment/Software:

  • 3D Printer
  • Raspberry Pi Zeros
  • Ribbon cables/connectors
  • Fusion 360
  • Power cables

Prototype

I was not sure how to execute what I wanted to accomplish with the Raspberry Pi holders. At first, I wanted to attach the holders to the front of the desk legs in the middle so that they were out of the way but still accessible. However, after we 3D printed them, we could not figure out a good way to create brackets to secure them to the desk legs. We also realized that this was impractical, especially if we wanted to use the GPIO pins in the future. This Pi holder design would also make it so that the table couldn’t be moved around since they would bind two tables together meaning that a new Pi holder would need to be designed if the desks were ever separated. This led to us deciding to make Pi holders that will individually sit on top of the desk, yet still look coherent when next to each other in the current setup.

Final

The final design allowed for us to put the Raspberry Pi holders at the corner of a desk with the Raspberry Pi Zero snuggly fitting in and having enough space for the ribbon connectors and power cables. This makes the Pi holders able to hold the Pi’s and the accessories needed to utilize them to their full potential. These Pi holders needed to work effectively, but also be appealing to the eye which inspired the design of the lid. To design the lid, I started by creating a SVG file of triangular patterns then importing that into the Fusion using the extrude tool to create the different depths.

Another thing that I added to the final design was vinyl labels to access the SSH and VNC. To do this, we had to set up two port forwards per Pi allowing for anyone to connect to the Pi’s if they are on Sacred Heat Wi-Fi. This will allow for users to be able to see the full desktop and GUI of the Raspberry Pi with VNC or to just use the command line using SSH. It also allows for all GPIO pins to be accessed and usable with a breadboard making it easy to attach sensors, so the Raspberry Pi’s are fully functional.

Categories
3d printing CAD - Design machine shop Project

Front Desk at the Makerspace

by Bryan Bushey and Trevor Neal

We designed the front desk of the makerspace at Sacred Heart University by using the Fusion 360 CAD software and the CNC Router known as the ShopBot. This wooden desk is used each day by staff as a receptionist desk. The second part of the desk is used for staff storage, and it holds a welcoming monitor for visitors.

Equipment/Software:

  • Autodesk Fusion 360
  • ShopBot
  • Epilog Fusion Pro 48 Inch
  • ¾ inch 4ft x 8ft Plywood
  • 3mm 12in x 24in Plywood

We designed the front desk using Fusion 360 keeping the thickness of the stock and multiple other measurements as ‘parameters,’ allowing us to alter the measurements seamlessly depending on future need-based changes. Some difficulties were that the wood sourcing in the design phase vs the final product. When we initially designed the desk there was supposed to be a sheet of butcher block. After some logistical challenges, we ended up deciding on a single ¾ inch sheet with stain to give it a polished look. The sides were painted white to match the surrounding room.

We worked on the 3D printed SHU wall that wraps around the model. To get the ‘SHU’ wall to look flush, we had to sand the entire face and apply multiple coats to get a smooth even finish. We only had a 3D printer bed size of no more than 12 x 12 inches, we had to slice the wall into 50 separate pieces for the flat section alone, and 24 pieces for the curved section.

To ensure the finger joints were appropriately placed, we cut out scale models. By scaling the 3/4in plywood to the 3mm plywood, the models were the exact proportions that the final product would be.

The main challenge was keeping in mind all the add-ons like the monitor and outlets. When designing it is easy to forget about the real-world parts that play into the design after it is built. Also being one of my first major CNC projects with the ShopBot, we did not have much experience with tolerances. By designing the CAD model with an exact thickness of 3/4 of an inch, it was harder to fit the finger joints together as there was zero give between parts. For this project on we used 18mm as the thickness because it allowed for a more forgivable distance that was more realistic.

Categories
3d printing CAD - Design Project

3D Printed Heart Magnets

For a Valentine’s Day event at the Idea Lab, I created a workshop that let users add their own custom text to a heart shaped magnet using Tinkercad. The Heart Magnets were designed with a 10.2mm x 2.6mm hole in the back to fit in the magnet. The hole was made slightly larger than the magnet so it would friction fit, but the magnets were very strong, so I had to add super glue. This was so the magnets would stay in the heart. This event also teaches the basics of Tinkercad and 3d modeling. This is done by them manipulating the size and shape of 3D models as well as combine objects and export them as STL files.

Equipment/Software:

  • Tinkercad
  • Prusa MK3S+ 3D printers
  • Overture PLA
  • 10mm Magnets
  • Super Glue

Step by Step:

  • Designed the Hearts in Tinkercad
  • Exported the file as STL
  • Created examples of the magnets with generic text to show people during the event what they should expect
  • Made a version of the Heart Magnets without any text so people would be able to add their own during the event

As this project was my first time creating a 3D model from scratch, it was challenging to enhance the shapes of the heart, thus making it more complex. The heart shape I ended up making had a raised border and was large enough to fit at least two lines of text. It was also challenging to teach all the students how to use Tinkercad, make sure their text was a proper size, connected to the 3D model and 3D printable.

It was interesting to do something like this instead of getting a 3D model from Thingiverse and printing it. This has helped my 3D design skill and knowledge. This event also required me teach students how to use Tinkercad. I have had experience teaching students how to use all the different types of equipment here at the Idea Lab because of my job as an Educator, however, this was my first time teaching 40 students how to 3D model.

Categories
3d printing CAD - Design Electronics - Arduino machine shop Project

Custom LED Lamps

by Bryan Bushey, Linnea Caraballo, and Trevor Neal

We designed custom LED lamps using LEDs and protoboards.

Equipment/Software:

  • 3D Printer
  • Wood
  • Soldering Stations
  • LEDs
  • USB Cable
  • Spray Paint

Electronics

We soldered 3 LEDs in parallel using a protoboard. We then took a micro-USB cable and cut off the USB end and stripped the wires so that it exposed the power and ground cables. We then soldered these to the LEDs so that they could be powered.

Final

The final design for the LED lamp was using a 3D printed lamp shade, a wooden base, and reusing hula-hoop parts to make the arm of the lamp. We then spray painted the base and hula-hoop part.

            This was one of the first electronic projects and workshops done, so it was a good way to get the hang of running workshops. It was also one of the first collaborative projects between multiple staff members and it allowed us to reuse parts that we no longer needed without having to throw them out.

Categories
3d printing CAD - Design Project

Shamrock Coasters

For our St. Patrick’s Day event, I let attendees write their own custom text on a 3D printed coaster with a shamrock on it. The coasters were designed as a disk shape with a raised lip on the edge. The lip is rounded into the disk to make a smooth slope up to the top of the shamrock shape. In the middle was a vector I found on the internet, and it is embedded 1.2mm into the coaster. The text is also embedded 1.2mm.

Equipment/Software:

  • Tinkercad
  • Prusa MK3S+ 3D printers
  • Overture PLA

Step by Step:

  • Designed the coasters in Tinkercad
  • Exported the file as STL
  • Made examples of the coasters with generic text to show people during the event what they should expect
  • Made a version of the shamrock coaster without any text so people would be able to add their own during the event

I tried making a coaster in the shape of a shamrock instead of just having a round coaster with a shamrock on it, but I was unable to make one that was visually appealing, so I just ended up using my original design. It also was difficult to get attendees to use the correct setting for their text so that the text was embedded into the coaster.

I learned a new 3D modeling software, onshape, to create first version of the coaster. This allowed me to learn a more advanced 3d modeling software. I now have the capability to create more advanced models. This event also helped my teaching ability as I had to teach a large group of students how to embed text into a shape.

Categories
3d printing Project

Words Matter Art Pieces

I was tasked with assisting Artist Mark Yurkiw in creating 3D scans of two of his art pieces, Yearning to Breathe Free, and Re-Birth of a Nation. The scans were modified to create miniatures of the art pieces to raise funding for the @#1 Main St. Galley Inc. a 501c3 non-profit raising awareness for local artist to local people. Yearning to Breathe Free will be sold at fundraisers and venues for the homeless as thank you gifts at certain donor amounts. Re-Birth of a Nation will be sold for fund raising events for children’s cancer research. I took the high-resolution scans using the Creaform Go!SCAN Spark 3D Scanner and modified the raw scans in Creaform’s VXelements program. For other modifications, I used Microsoft 3D builder, for example, the spokes on the Statue were too thin, so I used 3D builder to extrude the spokes. Originally, I 3D printed the prototype models on our Prusa MK3S and Ultimaker S5 printers, once I saw the quality of the prints, I determined that we should use SLA printing for a higher, more detailed resolution. We used the Formlabs 3+ and the Elegoo Mars 2 Pro for these demo prints.

Equipment/Software:

  • Creaform Go!SCAN Spark 3D Scanner
  • Creaform VXelements
  • Microsoft 3D Builder
  • Prusa MK3S
  • Ultimaker S5
  • PLA
  • Elegoo Mars 2 Pro
  • ABS Mint Resin
  • Formlabs 3+
  • White Resin

Step by Step:

  • The original art pieces to be scanned
Re-Birth of a Nation
Yearning to Breathe Free
  • 3D Scanned the two art pieces with the Creaform Go!SCAN and edited the models in VXelements
  • Re-Birth of a Nation in Prusa Slicer
  • 3D printed using FDM technology, lower detail
  • 3D Printed using SLA technology on Elegoo Mars 2 Pro, higher detail

During this project, the most challenging aspects were learning how to use SLA 3D Printing technology and learning to use the VXelements program to successfully scan objects in 3D.

Through the months working on this project, I learned the process of creating resin printing and understood what goes into creating a successful 3D scan, fully ready to be 3D printable.