Tuesday, 11 December 2012

Christmas Printing!

Seasons Greetings and Happy Holidays Everyone.

I hope you are all having a good end to the year, for me the last few RepRap months have been extremely interesting. Lots of machine testing and calibration, continuing and starting some new developments and printing a lot of presents for people.

More about machines and developments in the new year along with some overdue tutorials I plan to get completed over Christmas. - Have a great time and happy Christmas printing - Rich.


This is an advent Blog post for Christmas, my kids have been selecting Christmas things from Thingiverse to print out and put on their trees. I have been following and printing out the great advent calendar tree by Pleppik, other things have just naturally been printed out as presents and gifts.

Here is the progress with our printed Advent Tree - 

Days 1 & 2 - 
It starts with two nicely wrapped presents under the tree

Printed in Christmas Gold for the base of the tree.

Days 3 & 4 - 
Candy Cane  Sledge and an X-wing!

Trunk of the tree in woodland brown, Sledge is in punk star pink and X-wing in white and robot silver.
The Sledge is very fine, if you have a 0.5mm nozzle, you may wish to set the nozzle size to 0.35 if using Slic3r or it's not going to print out all that well.

Days 5 & 6 - 
Train and a bright white Snowman.

The train really needs some support to print correctly, I missed that and had a small shift in printing as the bottom got a little messed up, but it still fits in the box.


Days 7 & 8 - 
Glow in the dark candle and an orange coffee mug.

Green happens to be my favourite colour, so I tend to have quite a few different shades. I'm going for darker at the bottom, getting lighter as the tree gets taller.

Days 9 & 10 - 
Brown church and a slightly off-white igloo (Architects stone white).

We are starting to get some form and real colour to the advent tree. 

Days 11 & 12 - 
Gingerbread House and a Makerbot Replicator 2

The Gingerbread house needs support, or if you don't want to use support material then use my modified Gingerbread House here.

The Makerbot Replicator 2 model also needs support, but I have modified it slightly to allow it to print without any support, Get the non-support version here.

Days 13 & 14 - 
Tree in Nuclear Green ABS (the only bit in ABS so far) and the Gingerbread Man is in the much under used but so loved Buttercream PLA


Nuclear Christmas tree and a Gingerbread Man!


Days 15 & 16 - 

Bell and (good enough to eat) Candy Cane


The Awesome candy cane is printed in Awesome Aurora PLA from Faberdashery.co.uk - it's UV light reactive and changes colour from a wonderful light sugar pink to a stunning vivid blue.


Days 17 & 18 - 
 
Dr Who Tardis and a Pearl White snowflake
Day 18 had the 3rd different White PLA in this Advent tree, this time it's Pearly White, one of my favorite's
That's it for white now, if I need any more I'm going to have to get creative.


Days 19 & 20 - 

Day 19 was a Santa Hat, this is a little tricky to print in one part, and would require support material, I didn't fancy doing that, so I sliced it in half and glues it back together with a drop of superglue.


These boxes are printed in the 6th different Green plastic - Jade Green


The Day 19 Santa Hat is printed in the stunning new Mercury Red (Metallic PLA) - it basically makes anything you print look like a Super Hero, really fantastic material.

Day 20 is also a new Metallic PLA - this time Space Marine, totally intergalactic.

I'm almost out of different Greens - I did mention it's my favorite colour :) I have two remaining...


Days 21 & 22 - 

Some multicoloured prints - 
Burning logs (Brown,Red, Orange & Yellow)
Plate of cookies (White Plate, 'Butter cream' cookies, layer of 'Bling Bling gold' and 'Woodland brown')


The minty green was never going to really fit, but I wanted to use them all.



Days 23 & 24 - 


The Festivus Pole accompanied by a Grinchy Claus :)

And a super rocket!

Almost done !

Christmas Day - 


A snowy top of the tree, Bling Bling Gold star-burst and a Neon Cyber Yellow Star.


Have a great Christmas, Happy Holidays, Seasons Greetings !


Tree decorations - 

I'm loving this Gyroscopic snowflake by Roman_Hegglin, take a look on Thingiverse here.
It's BIG, and a great object, it's all printed in one go, when you pick it and move the rings a little the parts just start spinning perfectly!

Roman also has some smaller snowflakes on the Thingiverse link above, check them out.

My kids are selecting a thing a day to print, advent style to decorate their trees and rooms, here is the progress so far with links to the great Christmas models and designers on Thingiverse. 


For starters the great Christmas tree by TopperDEL

Most of these are printed in the fantastic Pearly white PLA by Faberdashery

And yes, that is a very pink Christmas tree!


Try to print the modern star if your printer's up to it!


And if you fancy even more twinkle for your tree take a look at the new Sparkle range from Faberdashery.
Space Marine and Mercury Red look amazing and if your giving a Raspberry Pi for Christmas get hold of some Raspberry Spark and print my version of the Super Pi case.


Really like this one, slightly tricky to slice if you are using Slic3r - make sure your nozzle size is about 0.42mm and you should get nice lattice work - 
Also set the first layer width to be the same as the rest for a nice looking print.


Snowflake by JonMonaghan - I have printed so many of these, they are great to print and look amazing especially in different colours.


Snowman by ChristineBowyer - This little snowman is a real family favorite, we have printed a lot of these in many sizes, I even printed some in Sugar paste earlier this year.


This one is a really interesting one to slice, you can go for a big nozzle width and get just shells for a very quick printing time, or a smaller fine nozzle and get a lot of tiny infilling slow print but a more filled look.

I also had some interesting differences with two recent Slic3r versions while attempting to slice this model, here is what I was seeing with Version 0.9.1 (my usual version at the moment) and testing out V0.9.5 

This was with Slic3r V0.9.1 - 0.42mm nozzle and 0.67mm single wall width, no infill - Slic3r makes a few little mistakes in the model but this GCODE prints well and quickly, the middle section is just loose enough to pop it out if you feel like it.
GCODE file is 200KB

This was with identical settings as above but with Slic3r V0.9.5 - This actually makes for a nice looking print but it has lots of tiny points of infill and a lot of extruder moves - it should also NOT be doing any infill, all filling and solid layers were turned off.
GCODE file is 250KB

This version is back to Slic3r 0.9.1 but with 0.42mm nozzle and 0.47mm single wall width, 20% infill, you really do end up with a dual ring around the snowflake, a nice print and quite quick.
GCODE file is 400KB

To test the infill problem of Slicer V0.9.5 I used 0.42mm nozzle and 0.47mm single wall width (as above) but had 0% infill and 0 top and bottom layers, this should give a hollow object, as you can see above it made a nice and filled star. This GCODE, 2.5MB and has some nasty high speed infills causing resonance in my printer and a massive number of extruder reversals, not one to print!

The photo hanging on the tree was with a slightly tweaked single wall size of 0.5mm GCODE was about 1.5MB Using Slic3r V0.9.5 - I never did manage to get a really nice print out of V0.9.1 but as Slic3r has moved on quite a few revisions now  I'll take another go with the next version as I type this it's V 0.9.7

A great little robot with support already designed into the model.



Traced Snowflake by Landru

Star Flake by IHeartRobotics

Little Green Man Christmas Ornament by gpvillamil printed in Jade Green

Angel by tc_fea -  Printed in Angelic pearl white and shimmering gold.



Gift Boxes -
Another popular present to print is the Extra Printable Companion cube by Keegi, this box is just perfect as a gift and can be scaled to any size easily.

The Original Companion cube upgrade was made by Landru, well worth a look if you don't want a box.


It also makes for an impressive Russian doll style stacking box set if you scale them to fit into each other.




Over the last few months I have printed more than I can count of these, the smallest being about 7mm and the biggest so far printed on a Rostock printer at about 186mm wide. 



The RepRap presentation at Cheltenham Geeks in November was great, lots of people turned up and we had quite an evening discussing all sorts of 3D printing and additive technologies. Thank you all for a great evening, can't wait to do it again. - I'll have the presentation and notes available soon (sorry for the delay)

Meeting in December (13th) for drinks and planning events and hacking for next year, see here and come along if you can.

Follow Cheltenham Geeks on Twitter here


Merry Christmas Everyone, and have a very Happy New Year!

Cheers,

Rich.


Thursday, 1 November 2012

Yearly RepRap adventures roundup 2012


Another year of RepRapping development adventures is over (for some historic reason my development season runs from October to the end of September each year)


In the last year’s roundup (2010-2011) I had the following to say – Link if you need a reminder.

This last 12 months have been intense and exciting and what a lot of changes this blossoming industry has seen.

Things I’m glad I got on and finished – (is anything ever finished?)

  • Universal paste and Chocolate printing, I had been thinking about this for well over a year before actually starting any testing, it was a good learning curve in 3D design (Sketchup) and iterative model testing.
    • I have countless people ask me about Chocolate printing!
    • It has had quite a few revisions and design changes by other people for other machines and bigger syringes
    • Parametric! Version by BonsaiBrain (ifeelbeta.de) - See Thingiverse for details

If you have not yet seen the wonderful video by RepRapBCN, take a look below!


  • The 3way extruder – Colour blending, lots of further potential, great fun doing it and seeing the first prints.

Joris Van Tubergen also made a 3 filament extruder, but his goal was to be able to extrude more filament for the amazing Kamermaker project his aim is to be able to extrude 1kg and eventually 5kg/hour of plastic.

Switching across to Slic3r and doing the tutorials was a good experience.
Part1 - Settings and extruder calibration
Part 2 - Filament calibrating and printing
Part 3 - How low can you go? - printing with small layers

I have been meaning to mention the various translations of the Slic3r tutorials out there and also a new getting started guide by Ivan Bortolin and Lorenzo Cantini - the main website Can be found here
The new guide in English PDF and Italian Here

Other translations of my Slic3r tutorials and extended work can be found in Portuguese, Russian, Spanish and Italian. - if you know of more do let me know.

Slic3r continues to move on and get stronger with more people using it every month.
If we had 3D printing awards Slic3r would get my vote for first place. My warmest thanks go to Alessandro for bringing Slic3r to all of us.


30 Days of creativity – Was hard work, but a very good focus for getting things started and having some fun with my printer.


I have really enjoyed printing more things for my kids this year, they love them!

It’s certainly easier when you have more than one printer up and running.

More group meetings with local RepRappers – it’s been a great year for getting people up and running.

Things I have not finished quite yet –

  • Geared Peristaltic Pump – I have grand plans, and it's working so well but it’s going to take more time before I can get back onto this. Keep an eye out on this development, I'm planning a dedicated printer to use it for something interesting.


  • Ceramic Printing, I had all the best intentions to do more ceramic printing, Precious metal clay printing and ‘other’ materials, but just not had the time to set it up again and have a good run at it. – When I think back I did the whole paste extruder development in about 2 weeks. - New 'RepRap year' resolution - 'find, use and develop more materials to 3D print with'



  • Further rounds of Polycarbonate printing, I started and then got side-tracked. I’ll pick it up again at some point along with other sorts of materials (Like Laywood).

  • My own machine development – Again started, many things worked out, but everything moves so fast it always needs a little rethink.
  • My design looks a little like the TK-O from LulzBot (Aleph objects), so I may take some more inspiration from that to finish-off my 'ultimate 3D printing machine'.
  • Recent time has been taken up with Rostock (see below) so what I learn from that and seeing how the TK-0 develops can go into the next revision



  • Rostock+, doing it now, but stalled a little for the last 6 weeks, need to build some more electronics. 
    • The ‘Plus’ part is for the use of Spectra fishing line (Like Tantillus below) instead of belts and pulleys, should look cool and be FAST!

  • More tutorials and guides, I have started some, it’ll be easier to focus on them in the winter, but I want to make it easier for people to get good 3D printing results and understand more things about the process. > Still learning every day myself!

Things I wish I had more time/resources for –


  • Actual 3D modelling and design, I’m planning to spend more time over winter doing 3D design and modelling, some organic and creative, other things more technical.
  • I want to learn Autocad123D as I have failed to spend any time with it this year – if anyone knows any good starting guide? – I have not really used the Autocad interface and I find it quite counter intuitive.


  • I have been inspired with so many works of 3D printing Art this year, far too many to mention, but ones you should really take a look at are the beautiful works by @Dizingof , the mechanical wonder of the planetary gears by aubenc and very stunning Trilobite’s! by AuntDaisy

     

  • Print challenges are Great! - (link to the RepRap forum printing challenges section) 
    • I love to print tricky models, it takes time to work out the best settings and it’s often different for each complex object, but hopefully we will continue to do challenges – they are a great way to learn ‘how to 3D print’

  • I do wish I had more time to meet more of the 3D printing community; we need a few more places to meet up during the next year. Any ideas? maybe video links?

  • Visiting more printing events and shows, they are great, but take time and money to attend. And are not very family friendly L very disappointed I could not make the London3Dprintshow and the 3D printing event in Eindhoven, but I did make it to a few events.

  • I also didn't use IRC as much as I wanted, started off the year using it, then also started on Twitter and didn't have the time to do both along with doing actual physical developments of things.
    • But I’ll get back on IRC soon, it’s a great community.

  • I answer a lot of e-mails and messages, and try to help people as much as I can, recently the RepRap forum has boomed with new people and questions; it’s hard to keep up!

  • I started a dedicated website (richrap.com), with the idea to show projects, tutorials, guides and general RepRap related developments. It needs more time spent on it, but it’s a start.

  • Software development, I should spend more time refining some of my developments (3way extruder to be automatic, more firmware integration) I need enough long periods of time to focus on it.
Things I have not started yet (but are on my list) –

  • Electronics – I was sure I would have time to do some real electronics development this year, but again so many new boards popped up, my own plans didn't need as much attention as I had thought- still we are some way off a real plug and play solution.
  • A really big printer! – I really wanted to do something like the Kamermaker (room builder) - cost, space and time just let me down, but I still have a vision for something not quite as big...
  • Concrete/cement printing – I’m seriously thinking about a good way to do this - anyone want to help me make it a reality?

  • Loss wax casting (with PLA) – Some good examples this year, would love to give it a go.

  • Resin printing – Almost got motivated to start on a LemonCurry, again didn't get time past reading all about the great project. – Interesting to see the Formlabs printer using a Laser and Resin just got over $2.9 Million on Kickstarter, Wow!

  • Experimenting with new support materials – I did just start doing this, some interesting results with sugar, needs a lot more work, Sugar seems very compatible with PLA.

  • Wax printing – Still not sure how best to move forwards with this – maybe try a new design of my heated universal paste extruder, it should work.
  • A Portable 3D printer - I still don’t have a true portable printer (folding or just easy to carry) – finishing Tantillus is my best option for the moment.

  • Lasers! – Powder and Sintering – I doubt I’ll be able to work on this area anytime soon! But it’s on the list!

I would still like to buy a new Lathe; still saving up…a few people have offered to help me out with new things needing machining – Thank you.

+++ Lots of stuff I have not even thought of yet !

Final thoughts - 

So, I have had some real proud moments in my 2012 RepRap developments; I have had fantastic people from all walks of life contact me. My work has been featured on lots of blogs and in magazines, interviewed, mentioned and cited in reports and academic works. I have done presentations and uploaded work and videos to university intranets and had people translate my projects into different languages.
Thank you all.

This is all open-source and as a hobby on a very teeny tiny budget, and I’m just one of many makers doing lots of things in this Great community.

The next development cycle has now started, I have some big goals for the next 12 months, no one knows where 3D printing is heading, and what it will look like in a further year, but it will continue to be exciting.

If you can make it, come and join us at Cheltenham Geeks in November, It's free but with limited spaces, go and register now over at meetup.com. Hamish and I will be presenting an evening of RepRap fun and developments, along with 3D printing demo's and beer, what more could you want? 


Thanks for reading; I hope you are enjoying the adventure, See you soon for more.

Rich.