Teen Maker builds a Cherry 3D printer for just $70

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This DIY FDM 3D printer may be among the cheapest ones ever.

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For young Makers, bringing an idea to life in the most inexpensive way possible is a top priority most of the time. Making that project look good on a limited budget is sometimes, well, even more of a challenge. That is unless, of course, you’re teenage Maker Johannes Rostek, who has developed an aesthetically-pleasing, fully-functional Cherry 3D Printer. Ever better? It costs less than $70 to create.

While many people out there would prefer to shell out some big bucks for a commercial machine, others rather channel their inner DIY spirt to craft their own printers from scratch. Using what he calls the “the cheapest motors on the planet,” Rostek employed four 28Byj-48 steppers that he had found on eBay, an Arduino Mega (ATmega2560) and RAMPS 1.4 for its electronics, as well as an all-metal hotend. In addition to that, he was able to obtain a couple MDF plates for the base, frame and print bed, along with nuts and screws from the local hardware store and a NEMA 17 that he happened to find lying around a junkyard.

The rest of the parts — including the Z-motor, Y-end, X-end, X-carriage, hotend and hotend clamp — can all be downloaded from Thingiverse. Plus, Rostke made use of a Bowden Extruder that is also available online.

After modifying the 28byj-48s by rearranging some connections, soldering a few wires and connecting them to the RAMPS 1.4 shield, the remainder of the project entails assembling all of the components. Rostek provides a breakdown of the steps required for piecing together each of the axes and constructing the print bed. From there, the Maker simply connected the electronics, installed the code onto the Arduino and uploaded it to Repetier for the complete firmware.

As one would expect from its composition, there are a few drawbacks when using the Cherry 3D Printer. In particular, the DIY device has a limited build volume of only 10cm x 10cm x 10cm. Nevertheless, it is still capable of printing those small objects pretty darn fast and with a decent resolution for the price. With just some minor calibrations, the 16-year-old Maker was able to extrude a 1cm x 1cm x 1cm cube with a resolution of 0.2mm and at a speed of up to 20mm/second.

Are you a Maker on a budget looking for a minimalist 3D printer? Head over to the project’s Instructables page here.

Robotic 3D printers will construct a steel bridge over Amsterdam waterways

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A group of designers will use an anti-gravity machine to 3D print a functional, life-size bridge in Amsterdam. 

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Apparently the Netherlands has become the hotbed for revolutionary architecture, particularly through the use of 3D printing. After following the completion of what may very well have been the worlds’ first full-sized, 3D-printed home, designers are now taking on another ambitious plan which will employ the combination of robotics and 3D printers. While Amsterdam has more than 1,200 bridges crossing the city’s waterways, one of those will soon be a bit different from the rest: the steel overpass will be constructed with a set of multi-axis printers that can draw structures in mid-air.

The machine, which is the brainchild of Dutch startup MX3D, will build the bridge over the one of the city’s main waterways, printing its own supports along the way. The anti-gravity apparatus will extrude in steel with special arms capable of heating up the metal to 2,732° F before welding the structure, resulting in a strong and durable pedestrian bridge.

Designed by Joris Laarman, the undertaking is a collaboration between MX3D, Autodesk, ABB Robotics, European construction company Heijmans and several others.

“I strongly believe in the future of digital production and local production, in ‘the new craft.’ This bridge will show how 3D printing finally enters the world of large-scale, functional objects and sustainable materials while allowing unprecedented freedom of form. The symbolism of the bridge is a beautiful metaphor to connect the technology of the future with the old city, in a way that brings out the best of both worlds,” Laarman writes.

The team has already tested the robotic printer by creating a complex metal sculpture of intersecting lines. That success inspired them to continue on with the project, which will include two robots working in unison — one starting on each side of the canal, both making their way towards the center.

Several designs of the bridge have been revealed, all of which involve a cantilevered arch. The final design, however, has yet to be unveiled. Both that, along with the exact location of the bridge, will be announced soon with completion slated for 2017.

Disney uses store-bought conductive thread to build robot muscles

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Researchers have developed an inexpensive way to make artificial muscles using off-the-shelf supplies.

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They say Disney World is the most magical place on Earth, but we’d argue that it may come second to their research lab. From 3D-printed plush toys to autonomous sand drawing robots to bipedal droids that walk like animated characters, the Disney Research team continues to dream up some impressive innovations that blend fantasy with the real world.

In an effort to make robotic arm automation more lifelike, a group of Disney engineers have found a way to develop strong, artificial muscles using inexpensive, store-bought conductive sewing thread coiled into a shape that resembles somewhat of a DNA helix.

“Natural muscles exhibit high power-to-weight ratios, inherent compliance and damping, fast actuation and high dynamic ranges. Unfortunately, traditional robotic actuators have been unable to attain similar properties, especially in a slender muscle-like form factor. Recently, super-coiled polymer (SCP) actuators have rejuvenated the promise of an artificial muscle,” the researchers write.

Movement is facilitated through the heating and cooling of the off-the-shelf strings. As the strands fluctuate in temperature, the cables contract and expand like a human muscle, which in turn, pulls the fingers causing the artificial hand to close. While the researchers initially set out to find a low-cost way to create artificial muscles, their project yielded controlled forces in less than 30 milliseconds — actually outperforming the capabilities of a human muscle.

“The average human skeletal muscle has a twitch cycle of over 100 ms, and reaches a steady-state force in hundreds of milliseconds. Furthermore, the peak power- to-weight ratio of mammalian skeletal muscle is 0.32kW/kg, whereas these actuators have been shown to generate up to 5.3kW/kg,” the team adds.

For their demonstration, Disney Research employed a 3D-printed robotic hand — which had been crafted using an AVR powered Makerbot Replicator 2 machine — comprised of four fingers and a thumb with actuators on each tendon enabling a full range of motion. The muscles were strewn along the forearm of the robot to mimic the physical locations of a human arm, while four small computer fans were used to cool the actuators during relaxation. As for its electronics, the arm was driven by an Arduino Nano (ATmega328) along with some simple MOSFET PWM-switching supplies.

“The robot arm was able to perform various grasping maneuvers. The grasps were performed in under a second without the benefit of any feedback sensor, using a lead compensator to improve the speed of finger motions. Each finger can be manipulated individually, and there was no noticeable crosstalk between actuators.”

Does this mean that in the future we’ll see more realistic movements by Disney automations at its parks worldwide? As we wait to find out, you can read its entire paper here.

Creating a mesmerizing DNA lamp for under $30

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You can’t help but stare this project. 

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Year after year, the Dark Room at Maker Faire Bay Area showcases some of the most engaging and stimulating visual presentations we’ve ever come across. Between the glorious glowing of lamps, the dancing of robotic lights and the brilliantly embedded garments strutting the runway, the room is a sight to be seen. And, well, this recent project from Portuguese Maker João Duarte would certainly fit right in.

With the help of 3D printing, Duarte was able to bring the mesmerizing DNA Lamp to life for less than $30 in supplies. A vast majority of the device’s parts were 3D-printed in black PLA filament with the exception of its acrylic tube and the electronics housed inside its base. He also used white glow in the filament for the helix in order to make it stand out more under UV light, and of course, to give it a nice green glow in the dark.

Merely a beginner when it comes to 3D design, the Maker turned to Autodesk’s Tinkercad software to help devise the project. Duarte employed two 3D printers for the job, his Prusa i3 that he had built himself and a LulzBot TAZ 4 from his local Makerspace. In total, the helix lamp took roughly 14 hours from start to finish.

As for the electronics, the Maker implemented an electric motor to provide the slow rotation of the DNA helix inside of the acrylic tubing. UV LEDs are embedded at the top and bottom of the tube, creating a fading effect when the lamp is turned on. Meanwhile,, a barebones Arduino Uno (ATmega328) handles the motor and the LEDs.

Beyond that, the Maker wanted to be able to manage the LEDs, power and the rotation of the helix. To accomplish this, he added a push button that selects the operation mode of the lamp, which of course is powered by the ATmega328.

In the end, Duarte wrote some code that enabled the UV LEDs to produce its slick visual effects, as the helix fluctuated between fluorescent hues to “give it the weird feeling of a mysterious evil experience or that it is alive somehow.” As you can see in the video below, the LEDs offer a pretty hypnotizing blue and purple glow.

Want one of your own? Head over to the project’s Instructables page here.

Controlling a motorized wheelchair with your eyes

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This DIY open source system enables those with ALS to drive their wheelchairs through eye movement.

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Amyotrophic laterals sclerosis, more commonly known as ALS, is a progressive neurodegenerative disease that affects nerve cells in the brain and the spinal cord. Motor neurons reach from the brain to the spinal cord and from the spinal cord to the muscles throughout the body. The progressive degeneration of the motor neurons in ALS eventually leads to their demise. When the motor neurons die, the ability of the brain to initiate and control muscle movement is lost. With voluntary muscle action progressively affected, people may lose the ability to speak, eat, move and breathe.

With that in mind, the Maker trio of Patrick Joyce, Steve Evans and David Hopkinson are currently working on a Hackaday Prize entry that will enable those with the disease, who no longer have use of hands, to operate their wheelchairs through eye movement. The project, called Eyedrivomatic, consists of a 3D-printed electronic hand that sits above the chair’s joystick and is given instructions by an Arduino Uno (ATmega328) based control unit, which in turn, commands the eye-tracking software.

ALS usually strikes people between the ages of 40 and 70, and approximately 20,000 people in the U.S. have the disease at any given time. The team ultimately hopes to provide an affordable and easily accessible method for those with motorized wheelchairs to take complete control of their mobility needs all through the power of sight.

Though both Joyce and Evans have access to Eyegaze equipment, the eye-tracking technology is only capable of operating a computer, not a wheelchair. As a result, the Makers wanted to create a device that could interface with the wheelchair-mounted computer, and then physically move the wheelchair’s steering joystick.

“I envisaged having two parts: an electronic hand unit and a brain box to control it. Making the [hand] should be fairly easy using servo motors, but I was stuck on what the brain box would actually be… then I discovered Arduino,” Joyce explains.

After ordering a 3D printer and waiting for it to arrive, he sought the help of Tim Helps who already had access to a machine, which they used to make a first prototype based on an initial mockup housed inside a cardboard box. Yet, the team found this version to be a bit too complicated and required a lot of soldering and custom parts in order to piece together. With a functioning proof-of-concept, a 3D printer on hand and a little help from the kind folks at 3D Systems, the Makers went on to build a second iteration of the Eyedrivomatic. This time, though, without the need of soldering and a wide range of components.

“Initially, I thought we’d interface the computer with the brain box via infrared, as most wheelchair mounted computers have infrared environmental control, but after consulting Steve I dropped this in favor of a direct connection via USB and got busy writing software for it in Processing,” Joyce adds.

When all is said and done, this DIY system is an inexpensive, open source way to give mobility back to people who thought they had lost it forever. Following a successful live test of Eyedrivomatic, the team has proceeded to develop a switch version employing Eyegaze for selecting direction and speed, and a switch for accelerating and stopping.

“It was very exciting, with everything working reliably and well. I will have to tweak the software a bit as the diagonal speed was disproportionately fast. With that done, the chair should change direction and speed smoothly in mid flow,” Joyce notes.

Now, the Makers have moved on to their latest model, which includes updated software, control box and electronic hand — all with the goal of making it easier to build. By November, the trio hopes to have a couple of next-generation Eyedrivomatics in use by ALS sufferers along with comprehensive set of instructions available online.

This is truly amazing and is exactly what this year’s Hackaday Prize challenge is all about. You can read more on the project’s official page, as well as check out the machine in action below!

Researchers 3D print in metal using tiny droplets of gold and coper

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A team of Dutch researchers have discovered a way to 3D print metal structures of copper and gold.

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Evident by recent advancements, 3D printing has become a rapidly evolving field. However, at the moment most machines are limited to plastics and other kinds of softer filaments. Looking to change that, one team of Dutch researchers at the University of Twente have discovered a new way to print metal structures using microscopically stacked droplets of copper and gold, melted by a pulsed laser.

“If metals could be used for 3D printing as well, this would open a wide new range of possibilities. Metals conduct electricity and heat very well, and they’re very robust. Therefore, 3D printing in metals would allow manufacturing of entirely new devices and components, such as small cooling elements or connections between stacked chips in smartphones,” the team writes.

As a major step towards high-resolution metal printing, the group of researchers used a laser to melt copper and gold into micrometer-sized droplets and deposit them in a controlled manner. With this method, a pulsed laser focuses on a thin metal film that locally melts it into a tiny droplet. From there, the drops are carefully positioned onto a substrate to form a disc-like shape, which enables researchers to repeatedly stack them on top of each other to create a sturdy, high-resolution 3D structure..

The team claims that it was able to stack thousands of metal drops into a tiny pillar just 2 millimeters tall and 5 microns in diameter, as well as just about any shape including electrodes and copper circuits. Admittedly, this method still requires some refinement as the high-energy laser currently causes droplets to also land next to the desired location. The team plans to look into this issue to improve its printing capabilities not just in metals, but also metals, gels, pastas and extremely thick fluids.

Intrigued? Read the project’s entire article here.

Building a $60 SLA 3D printer with LEGO and K’NEX

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Don’t want to spend big bucks on an SLA printer but tired of FDM? Make your own with LEGO, K’NEX and Arduino.

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While the market for 3D printers has surely grown throughout the years, up until now a majority of Makers have turned to Fused Deposition Modelling (FDM) machines. These work by heating a material, extruding it out of a moving nozzle and giving it time to cool. On the contrary, Stereolithography revolves around UV lighting to harden the liquid resin, which enables Makers to create projects in one piece and with smoother surfaces. However, this convenience comes at a cost. Those seeking a higher resolution print have no choice to dig deep into their wallets for an SLA device. Unless, you are Instructables users “mastsermind,” who has created one for less than $60 using some LEGO bricks, K’NEX pieces and a few other electronic components.

Inspired by the mythological creature comprised of three different animals, the Chimera 3D printer is made up of recycled parts from three different categories: projectors, toys and old computers. What’s impressive is that the unit doesn’t entail a whole lot of parts: just a projector, a computer disc drive laser deck with stepper motor, any ATmega328 based Arduino, an EasyDriver v.4.4, some tools and wires, along with the option to etch a circuit board and construct a wooden frame. That’s it.

“Top down DLP printers in their simplest form have only one axis of motion, a video projector, and minimal electronics. They do not require a heated or perfectly level bed, there is never a clogged or wrong temperature in the extruder as it does not use an extruder. And the resin used has a comparable price to FDM printers,” the Maker explains.

The Chimera was built around two frames, one of LEGO to hold the Z axis, platform and resin tank, the other of K’NEX to hold and move the projector. Beyond that, the resin tank can basically be any container that’s waterproof and strong enough to hold the solvent.

Obviously, the most important component of the system is the projector, which matsermind employed an inexpensive Mitsubishi XD221u. He does recommend staying above a 1024 x 768 resolution for optimal results. In order to make this suitable for printing, a few modifications are required such as getting the focus distances closer and removing the UV filter to allow for more light through.

“Making it cure the resin faster is easy, just remove the filter (glass square) on the front of the bulb.  Making the projector focus at ≈7 inches was a bit more difficult. The service manual has been attached for assistance in disassembly if you are using an XD221u projector, but the modification should be similar for most projectors,” the Maker reveals.

Meanwhile, the Z axis consists of a laser deck assembly from an old computer disc drive. An Arduino is tasked with driving the stepper motor salvaged from the drive and ensuring it moves at the right rate.

“The one I used is one that I have had around for a while, waiting for a good use for it. I do not know what model drive it came out of, but any assembly will work as long as it uses a stepper motor with four wires and not a DC motor with two wires,” he adds.

What’s nice about a top down system is the simplicity of its electronics. Whereas a vast majority of complex printers today are embedded with the combination of an Arduino Mega (ATmega2560) and a RAMPS 1.4 shield, this machine only requires an inexpensive Arduino Uno seeing as though there is only one axis to control.

“If you want to put a little more work into it, you can program an ATmega328 chip with the firmware and etch an all-in-one board whose design is included in the files attached,” matstermind notes.

In terms of firmware, the Maker selected GRBL 0.9i and runs the open source Creation Workshop software on it. While as fully-functional as it may be, mastermind has a few more plans for Chimera in the weeks to come. These include increasing the size of the resin tan, designing a wooden frame out of MDF or particle-board shelving, enhancing its stability, as well as adding a shutter attachment to prevent the resin from being exposed to accidental light.

Intrigued? Head over to the project’s elaborate Instructables page here.

This open source machine lets you knit your own clothing

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Now that’s what we call doin-knit-yourself!

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Circular knitting is a form of knitting that creates a seamless tube. In recent years, knitting in the round has gained tremendous popularity among crafty DIYers, particularly those hoping that the rhythmic click of needles and repetitious weaving of yarn would alleviate some stress. For other hobbyists, the joys of knitting lie in the process of designing an automated machine to do the tedious task for them, as seen with the Maker duo of Varvara Guljajeva and Mar Canet who have developed an open source circular knitting machine, aptly named Circular Knitic.

Though digital knitting may not exactly be a form of additive manufacturing, the project does share a number of commonalities with 3D printing. As 3D printers continue to gain mainstream appeal, the fashion industry has become one of, if not, the quickest to adopt the next-gen technology. In fact, many designers are slowly introducing FDM printing into their prototyping labs, with several others already having fully-embraced these devices as a fashion tool — evident by the accessories seen throughout Eureka Park back at CES 2015 and dresses taking the runway at Fashion Weeks across the world.

Initially built for a program called DOERS, which was curated by Arduino co-founder David Cuartielles, the open source machine was constructed using a series of RepRap, MakerBot and Ultimaker 2 printers for most of its components, along with some digital fabrication, laser cutting and MakerBeam. Much like the tool we saw last year that was capable of threading pieces of attire, the OpenKnit, Circular Knitic is also powered by an Arduino — an Uno to be exact (ATmega328).

The brainchild of artists Varvara Guljajeva and Mar Canet, these desktop-sized machines are currently being commissioned to create long scarves at Etopia Center for Art & Technology in Zaragoza, Spain through July 31, 2015.

Similar to how a RepRap FDM printer extrudes plastic in various shapes, the Circular Knitic produces specific patterns of wool to form woven strands of clothing, ranging from scarves to gloves to keep you warm this winter. Even better, since its creators have made the files available on GitHub, users can simply 3D print and assemble the desktop device at home to make their own garments without having to ever head out to the store!

“Fab Labs and Makerspaces are a lot about hard-surface object production. At the same time, the first digital fabrication tool, which is an electronic knitting machine back to 1976, has been forgotten and discontinued. Hence, with this project, Circular Knitic, and our earlier one called Knitic, we aim to integrate textile fabrication to the Makers’ culture.”

Interested in starting your own in-home knitting factory? You’re in luck. The Maker duo has provided a step-by-step breakdown of the build on Instructables, in addition to having submitted their project as a contender for this year’s Hackaday Prize. Want to see more photos? Guljajeva and Canet have shared an entire album here.

SeraMaker is an open-source, Arduino-powered 3D printer

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This open-source 3D printer was inspired by the RepRap Prusa Mendel i2. 

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The brainchild of an Italian Maker “SebaSera94” as part of his a project at the Istituto D’Istruzione Superiore Giacomo Floriani, SeraMaker is a RepRap-inspired 3D printer.

Based on the Prusa Mendal i2, this FDM machine is comprised of six pieces of medium-density fiberboard ranging in thickness from five millimeters for the base to 12 millimeters for the casing. The windows of the printer are fixed from the inside with the exception of the front, which is attached via hinges to allow for opening as well as magnets and a metal plate located behind the handle for closure.

Like with a vast majority of these open-source units, an Arduino Mega (ATmega2560) and RAMPS 1.4 serve as the brains of the operation, while stepper motors are tasked with generating the motion axes with precision. Five motors are embedded inside the device in total: two to actuate the X and Y axes, two for the Z axis and one to drive the filament through the extruder. In terms of firmware, the printer was configured using Marlin.

SeraMaker boasts a 20cm x 20cm bed which uses imprinted copper coil to act as electrical resistance and heat the print surface. Four LED lamps provide lighting for the machine, three of which shine onto the printing plane from various angles while the other illuminates SeraMaker’s name tag.

All of the electronic components, including the ATX power supply and junction box, are housed inside the lower portion of the structure. There also lies the ATmega2560, control motors, a display to access its navigation menu, a relay to separate the power circuit of the heating plate, a card to control LEDs and a small 50mm fan for ventilation.

“To the rear panel are fixed two connectors and as many switches,” SebaSera94 adds. “The USB connector is an extension of the same port of the Arduino board to allow rapid access to a computer while the power supply is connected to the 230V AC via the connector, which is connected in series with the switch for disconnecting general. The remaining sections switch the lighting circuit from the 12V line.”

Other than the structural and mechanical components, the fiberboard and plexiglass housing, each of the machine’s parts can be 3D-printed. Just head over to its Thingiverse page here.

This 3D printer is made of LEGO bricks

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Don’t let its appearance fool you, this LEGO machine will work just as good as any Prusa i3 printer.

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Reminiscing about your earliest years as a Maker will surely conjure up some memories of interlocking multi-colored plastic bricks. Since its debut in 1949, LEGO has remained synonymous with DIY, especially for the younger crowd. As of late, we have been seeing quite the convergence of the 3D printing and toy worlds, ranging from Disney to Mattel, with hopes of delivering customizable items on demand. And who’s to say that it only has to be for child’s play? One Maker has proven just that by devising a fully-functional 3D printer comprised of, well, LEGO pieces.

The brainchild of Gosse Adema, the so-called LEGO 3D Printer is based on the framework of a Prusa i3 printer. Originally conceived as an A4-plotter with stepper motors from an old HP printer, the Maker had decided to upgrade to Nema 17 stepper motors and transform it into a slick X, Y and Z axis machine.

Though a quick online search may reveal a number of LEGO-based 3D gizmos, none of them may be as impressive as this one. Made up of default-sized bricks (four by two studs at 32mm x 16mm x 9.6mm), this innovative contraption is capable of extruding plastic like any other desktop device. The printer boasts a base of 34 x 64 studs (19.2cm x 51.2cm), which determines the exact location of the Y axis, along with a height of 44 blocks (42cm) and a sturdy L-frame that’s 36 blocks tall. This, of course, dictates how high a printed object can be.

Keep in mind, as with any LEGO project, the taller the structure, the more unstable the frame becomes. For support, the Maker ensured that every fifth piece was a technic brick. And unlike the X axis of a Prusa i3 consisting of a separate left and right side connected by two rods, Adema instead implemented one large X axis using long technic bricks for enhanced stability. Beyond that, Nema 17 steppers are attached to the technics using a felt damper/isolator and M3x15 bolts, giving it a robust base.

Adema makes it known that he did not use any Mindstorms product for this build. Whereas most LEGO printers employ servos, this design worked quite nicely with stepper motors. As with any Prusa i3, this device was powered by the incredibly popular combination of an ATmega2560 MCU with a RAMPS 1.4 shield. The motor responsible for driving the entire operation is held in place with technic bricks at the back. In terms of software, the gadget uses Marlin for the ATmega2560, while running Pronterface on his laptop to control the printer.

In his Instructables post, Adema explains in great detail as to how he assembled the frame, completed the X, Y and Z axes, added each of the three endstops, attached the threaded rod and installed the Geeetech MK8 extruder. What’s more, the heat bed is capable of reaching 110° C, while the printhead starts at 170° C. The Maker notes that prior to installing the Marlin software, a few changes to the printer and its configuration were necessary.

“My first print had some problems with the amount of filament but everything worked. The main problem was the difference in filament settings and extruder nozzle. This was caused by the Pronterface settings,” the Maker writes. “This resulted in feeding too few filament. Next error was the default nozzle size is 0.5 mm with a layer height of 0.4 mm. The actual nozzle is 0.3 mm.”

This simply meant that he had to adjust the settings a tad, aside from calibrating some of its parts.

“Although the printer needs to be further calibrated everything is working properly,” Adema concludes. “By ensuring that all axes move smoothly, no steps are skipped by the stepper motors. This was one of the problems during the first print.”

As with any LEGO project, having the ability to modify the gadget after it’s constructed is certainly an advantage. While it may look like a toy at first glance, this 3D printer can actually create some credible 3D models. Sound like a unit you’d love to try? Head over to the Maker’s elaborate tutorial on Instructables here, or watch it in action below!