3D printing a working 5-speed manual Toyota transmission

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Maker 3D prints a fully-functional 5-speed transmission for a Toyota 22RE engine.

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You may recall a project from back in January when auto enthusiast Eric Harrell replicated a Toyota 22RE four-cylinder engine using a RepRap Prusa 3D printer. Not only did it aesthetically fit the bill, it was completely functional as well. Following such positive feedback from the DIY community and media coverage around his earlier design, Harrell decided to complement his creation by 3D printing a 5-speed manual transmission modeled after a W56 Toyota. Combined, the two components form an impressive piece of DIY machinery!

“This is the 4WD version of the transmission so it has a mounting surface to bolt a transfer case to. I’ll work to get a 2WD housing designed up, since the only difference is the rear section of the transmission. The transfer case will be the next thing I will upload,” the Maker writes.

The build took Harrell just over two days to finish, which was accomplished using his ATmega2560 powered Kossel Mini printer. Upon completion, the transmission worked — all 5 speeds and reverse. The project utilized a decent amount of 3mm rod and 623zz bearings, along with some screws and nuts given the tiny size of a few of the parts.

Interested? You can check out the entire project on Thingiverse here. Meanwhile, watch it in action below!

UC Berkeley 3D prints an entire 9-foot-tall pavilion

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Researchers have just 3D-printed the first and largest powder-based cement structure.

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A team of researchers from UC Berkeley’s College of Environmental Design has unveiled what they’re calling the “first and largest powdered cement-based, 3D-printed structure.” 

To be clear, this isn’t the first 3D-printed building. If you recall, a Chinese company recently constructed 10 homes in less than day and finished an entire apartment block back in January using 3D-printed parts. Aside from that, a Dutch design firm has already devised a canal house in Amsterdam, a New York architect planned an entire estate and a Minnesota Maker created a castle all through additive manufacturing. However, what sets this project apart is that it was constructed using dry powdered cement, whereas its predecessors were made by extruding wet cement through a nozzle.

The pavilion, which goes by the name Bloom, is 9′ tall, 12′ wide and 12′ deep, and dons a traditional Thai floral motif design on its exterior to allow for natural light to shine through its interior in daylight and glow like a luminary at night. It is composed of 840 custom-printed blocks, each comprised of an iron oxide-free Portland cement polymer, and fabricated using 11 3D Systems printers.

“This project is the genesis of a realistic, marketable process with the potential to transform the way we think about building a structure,” explained Ronald Rael, Associate Professor of Architecture at UC Berkeley.

What really sets this unique system apart from existing methods of extrusion is that, by using an iron oxide-free Portland cement polymer formulation, Bloom is able to overcome many of the previous limitations to 3D-printed architecture. These constraints include the speed and cost of production, as well as aesthetics and practical applications.

Undoubtedly, 3D printing has transcended well beyond just mere plastic figurines, with today’s advanced printers — many of which powered by Atmel | SMART and AVR microcontrollers — capable of producing everything from functional tools in space to automobiles to entire buildings. After its official unveiling, the Bloom Pavilion was disassembled and shipped to Siam Research and Innovation in Thailand, where it will be exhibited for a few months before touring the world. Those wishing to learn more can head over to the project’s official page here.

Artists bring an animation to life with 3D printing

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A group of designers have animated an adventure of 100 frames and froze it into a 3D-printed installation. 

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Nearly 20 years ago, Toy Story became the first-ever feature-length, computer-animated film. Produced by Pixar Animation Studios and released by Walt Disney Pictures, the movie followed a group of anthropomorphic toys who pretend to be lifeless whenever humans are present, and focuses on the relationship between a pull string cowboy doll and an astronaut action figure. After after seeing a mesmerizing installation from Dutch design studio Job, Joris & Marieke, and given recent advancements in additive manufacturing, we couldn’t help but wonder when the first 3D-printed animated flick will hit theaters?

Using just an Ultimaker 2 printer along with some glue and string, the Netherlands-based artist trio created a brief loop as part of an entirely 3D-printed sequence. The artists then took the digitally animated short that they had on video and showed what every frame would look like using actual figures, packing all 100 frames into a mise-en-scène.

At a glance, viewers can see a character emerge from a piece of paper and run over a table inside a room that resembles the Job, Joris & Marieke studio. He proceeds to push a bouncing ball off the tabletop along with shattering a cup, not long before he eventually jumps into a preserving jar on a shelf. Each of these were reproduced in PVC.

“The whole animation is made in CGI, and we used a 3D printer to print each frame. The result is a weird string of characters in different poses. This explains the principles of animation beautifully, without a single bit actually moving. It is a static installation: a frozen movement. If you look closely, you can figure out what happened on that table,” its creators explain. “No one knows why he’s in such a rush. All we know is that he doesn’t want to be recognized…”

The aptly-dubbed piece, “FREEZE! An Adventure in 100 Frames,” will be on display at Amersfoort’s Kunsthal Museum as part of the MOVE ON…! exhibition, which debuts on March 29th and runs through May 10th.

Creating a synchronized string fountain with Arduino

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This kinetic sculpture uses propulsion to elevate a continuous piece of string into the air.

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There’s just something about fountains with their synchronization, fluid movements and translucent colors that can instantly captivate the attention of viewers. But what about displays that don’t use water? That is what one artist has set out to do, with a project he calls the String Fountain. Replicating the likes of the Bellagio world-renowned display mixed with a 1950s synchronized swimming performance, Paolo Salvagione has created a kinetic sculpture that uses propulsion to elevate a continuous piece of string into the air during his residency at Autodesk’s Pier 9 facility.

By no means is pushing string with a motor a brand-spanking new concept; however, adding a few servo motors and an Arduino to create an automated installation certainly changes the game. Connected to a PC, the Atmel based board is tasked with controlling the vertical and horizontal tilt and its rotation using a pair of bilateral servos. Meanwhile, the motor pull speed ensures that the string remains elevated as the two servos tilt left and right to keep the string in the air.

Similar to other multi-spout fountain displays like at Disney’s EPCOT, the final installation includes six different strings, each of which are kept in the air simultaneously reacting to the presence of visitors. Interested? A detailed breakdown of the project, whose parts were almost entirely 3D-printed, can be found on Instructables. In the meantime, you can watch it in action below!

Creating a 3D-printed automatic fish feeder

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Helios Labs has designed an automatic fish feeder using Arduino and a 3D printer. 

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Aquaponics is a food production system that combines conventional aquaculture (such as raising aquatic animals) with hydroponics (cultivating plants in water) in a symbiotic environment. Fish are the power house of any good aquaponics system, as they provide the nutrients for the plants. In an effort to ensure that the creatures are properly fed, the crew over at Helios Labs has come up with a DIY solution. The Makers recently created a 3D-printed fish feeder that hangs from a planter over a tank in an aquaponics system.

The project was programmed with a rather simple code that works by feeding the fish twice a day — once when first plugged in and then again several hours later using a “delay” function. After the fish are fed for the second time, the delay function is called upon again in order to wait until the original starting time, which in their case was 7am.

The unit itself is comprised of a hopper that holds the fish food, as well as 3D-printed auger that is superglued to the gear of a 9g micro servo. In between feedings, the servo, which is controlled by an Arduino Uno (ATmega328), is detached as it can only rotate about 180 degrees. The auger was designed to prevent the fish food from accidentally entering the electronics compartment.

“Ideally you should connect the servo to its own 5V power source and power the Arduino via a USB/DC adapter separately. The servo, if powered by the Arduino directly, might overdraw amps and reset the Arduino. This will essentially ruin the timer’s accuracy and require you to reset it,” the team writes.

If any of you have ever owned fish, then you know how easy it can be to forget to feed poor little Nemo from time to time. Good news, Helios Labs says that they will also be creating one for in-home tanks as well. Interested in learning more? Head over to the project’s page here.

3D printing your own remote-controlled Mars Rover

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This DIY project is out of this world! 

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Over the last couple of months, we’ve seen a number of objects successfully 3D-printed in zero-gravity by our friends at Made In Space in collaboration with NASA. These efforts are mere proof that 3D printing applications will soon transcend beyond just simple tools and small components, bringing us one step closer to future manned missions to Mars. Aside from professional endeavors, Makers have also taken part in exploring extraterrestrial use cases, ranging from an intergalactic-bound printer that could potentially enhance self-sufficiency for astronauts to autonomous bots capable of extruding in hostile environments using materials it finds.

And, if using additive manufacturing to create entire communities and sustain life in space are within reach, surely a 3D-printed rover is pretty realistic as well. Inspired by NASA’s Curiosity Rover, Maker Josef Vladik has built his own 3D-printed Mars Rover using a RepRap Rebel 2 and an Arduino Mega (ATmega2560).

Controlled by a standard 4CH transmitter, the device features four standard channels, a 2S or 3S lithium polymer battery and 9G servos with metal gear modded for 360 degrees of rotation. Beyond that, the rover precisely traverses the terrain using its nine compact wheels, while mounted LED floodlights round out its realistic appearance from both the front and back.

Think you’d like to give it a shot and make a rover of your own? You can find an entire breakdown of the build including parts and files here.

STACKER is a modular, commercial-grade 3D printer

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This commercial-grade 3D printer lets Makers print up to four objects at once.

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While 3D printers on Kickstarter are seemingly a dime a dozen these days, those that are capable of garnering nearly $200,000 in funds are much rarer. The Stacker 3D team recently joined forces with filament manufacturer ColorFabb to launch what they’re calling an “affordable commercial-grade 3D printer” dubbed STACKER.

Most commercial 3D printers on the market today are not only extremely slow, they’re ridiculously expensive as well. As a result, Makers are left out in the cold with no other choice than to turn to consumer-level machines. This is something the Minneapolis-based startup is looking to change. Designed with offices, schools, Makerspaces and small to medium-sized companies in mind, STACKER boasts a number of unique features that will surely set itself apart from the ever-growing 3DP pack.

For one, the machine is equipped with multi-print technology that enables users to print up to four of the same objects at the same time, and with up to four different extruders, the objects can even be extruded in various types of filaments. STACKER has three modes: single-part, Multi-part, and multi-material.

• Single-part mode: Print one part with one print head.
• Multi-part mode: Print multiple copies of the same exact part. This mode uses one head per part.
• Multi-material mode: Print one part with more than one material type. This mode allows users to extrude multiple materials from more than one hot-end onto the same part.

STACKER is available in both desktop and mobile configurations. Users can add its full height frame option to their desktop model and caster option, and can have an ultimate mobile printer right then and there. The casters have a built-in suspension system for smooth rolling. The industrial-duty gadget also has an expandable Z-axis, meaning users can easily increase the printing height of their desktop printer from 220mm to over 600mm. What’s more, the recently-unveiled printer packs a huge build volume. Desktop models posses a print size of 250 x 450 x 220mm, while full height mobile models have a print size of 250 x 450 x 600mm.

“STACKER is more than just a fast and affordable commercial grade 3D printer; it’s also highly functional. For example, it can print huge and tall parts, up to 24” (600mm). This invention opens up a whole new world of possibilities. STACKER also ships with our new HYBRID hot-end. This reliable new hot-end was optimized to extrude our new generation of high tech composite filaments,” STACKER founder Norston Fontaine explains.

STACKER’s versatile hot-end enables super quick nozzle changes, which come in two different types: one for lower melt filaments (like PLA and ABS), the other for higher melt filaments (like Tg Co-polyesters and some nylons). Meanwhile, the aptly named HYBRID was specifically designed to run composite filaments like ColorFabb’s new carbon fiber XT-CF20, and uses a special grade of stainless steel to dramatically improve nozzle life.

“By engineering two different nozzle types, we have eliminated jamming and other common hot end failures. Quick change nozzles also make it easy to change tip sizes,” Fontaine adds.

Furthermore, STACKER has custom polymer bearings that can be adjusted to achieve extremely tight tolerances. As the company notes, these bearings do not use grease or oil, nor do they require any maintenance. These bearings can also be used in harsh environments filled with contaminants and moisture, and are highly-effective at absorbing vibrations. Unlike with metal, composite bearings do not cause accelerated shaft wear during rapid back-and-forth movements, which is very common with 3D printing.

Built around an AZTEEG X3 PRO (ATmega2560), the device has a maximum print speed of 150mm/second, a top travel speed of 250mm/second and can be connected either by USB or SD card. STACKER runs on its own customized version of Repetier and is compatible with other 3D printing software, such as Cura, Slic3r, Pronterface and Simplify3d.

Other notable specs include:

• Printer size: 26.5” x 15.75” x 28” (675mm x 400mm x 720mm)
• Print area:
  • MAX X/Y print area one head printing: 10” (255mm) x 18” (458mm)
  • MAX X/Y print area two heads printing: 10” (255mm)  x  8.7” (220mm)
  • MAX X/Y print area three heads printing: 10” (255mm)  x 5.46” (138mm)
  • MAX X/Y print area four heads printing: 10” (255mm) x 3.9” (100mm)
• Printer weight: 30kg (65lbs)
• Nozzle diameter: 0.5mm (option nozzle sizes: 0.3mm, 0.4mm, 0.6mm, 0.8mm and 1mm)
• Build plate: Tempered glass, sandblasted, removable
• Print bed: Heated, custom PCB, 250 WATT
• Layer Resolution: 100-1000 microns
• Filament type: Most all types of high-quality filament, 1.75 mm diameter
• Connectivity: USB, SD card
• Power supply input: 100-240VAC 8.5A
• Power supply output: 27A at 24VDC
• Operating temperature range: 50-100 °F (10-38 °C)
• Operating noise: 35-70 dB

Interested? Head over to STACKER’s official Kickstarter page, where the team has already nearly doubled its initial $100,000 goal. Shipment for early bird backers is expected to begin in June 2015, with regular delivery slated for July 2015.

SmartrapCore is a low-cost, open-source wooden box 3D printer

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SmartrapCore is the company’s second model and is even easier to assemble than the Smartrap.

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As the popularity of inexpensive, open-source 3D printers continues to grow amongst the DIY community, Smartfriendz is hoping to help accelerate adoption with their latest device, the SmartrapCore. Touted as a “true RepRap printer,” it is capable of constantly improving itself by printing its own plastic parts and upgrades. Possessing the same ease-of-use as the French startup’s earlier Smartrap 3D Printer, Makers will be able to access online plans, instructions and assembly assistance through a series of tutorial videos.

However, in an effort to differentiate itself from the Smartrap, the team started the project with a coreXY base. (Hence, the “core” in its name.) The 3D-printed components are placed inside and atop of a wooden box, then simply screwed in using wood screws. As for its hardware, like a number of other RepRaps available today, the SmartrapCore is based on an Arduino Mega 2560 (ATmega2560) and a RAMPS 1.4 control board.

Smartfriendz shares that the machine is expandable from 20cm x 20cm to around 50cm x 50cm. More importantly, all designs are entirely written in OpenJSCAD along with various NEMA, rod, print and wood thickness sizes. All models are dynamically updated from parameters, while print plates will soon be automatically generated. Beyond that, the team has recently made improvements to reorient the stop on “new plate2,” as well as the J-Head attachment with its inductive sensor.

Interested? Not only can you now purchase the SmartrapCore online, you can also find its files on Thingiverse and Github.

Mini Metal Maker is an affordable metal clay 3D printer

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This machine will let you print your own jewelry, ornaments and clips. 

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Have you ever wanted to design your own custom jewelry, metal findings, sculptures, specialized machine parts and ornamental hardware? Well, you’re in luck. Thanks to David and Lindsay Hartkop’s latest Indiegogo project, we may be closer to a world of affordable, in-home metal 3D printing. The aptly-dubbed Mini Metal Maker is a self-contained device that is hoping to provide Makers, artisans and artists alike with the ability to inexpensively print items using a special blend of clay materials from manufacturer Metal Adventures.

The incredibly sleek, compact printer functions in a similar fashion as to countless other Cartesian-based FDM machines available today. However, the key difference is that the Mini Metal Maker constructs 3D objects from digital files directly in metal clay, rather than in thermoplastic. Its sturdy steel and aluminum frame is packed with an all-electromechanical extruder and provides over 300 PSI. Beyond that, the desktop gadget can automatically sense extrude nozzle height, thereby making nozzle changes easier than ever before, and is digitally-controlled enabling quick starts and stops.

The machine itself is based on an Arduino Due (SAM3X8E) running modified Sprinter-based open source firmware. The Mini Metal Maker can also be used with open-source host and slicing software such as Printrun and Slicer, and according to its Indiegogo campaign, the Hartkop’s are in the midst of developing a cross-platform work environment for loading objects into the printer. Its compact size — measuring in at 9” x 12” x 18” —  allows for the device to rest on any desktop or counter without taking up too much space.

What’s nice is that the machine is equipped with a removal magnetic bath, which will help prevent clay from dying inside the nozzle. In addition, it prints on removable magnetic vinyl sheet, which the metal clay clings to when wet and automatically releases when dry. This makes the process as easy as printing the object, trading the plate and beginning a new print.

Upon being printer, designers can work on and clean up their creation before firing it up in the kiln. Once heated up to 1550˚F(600˚C-900˚C), the clay piece becomes an entirely metal object that can be bent, filed, polished, drilled and even soldered.

• Printer size: 9” x 12” x 18’” (23cm x 30cm x 46cm)
• Build envelope: 8cm x 8cm x 8cm
• Printer weight: 10lbs
• Extrusion resolution: 250 microns
• XY resolution: 10 microns
• Z resolution: 2 microns
• Connectivity: USB
• Filament: Metal Clay

The Mini Metal Maker is the perfect tool for any jewelry artisan, artist or Maker. Whether you’re interested in devising some custom jewelry, ornaments, or even some gears and clips, you may want to hurry over to its official Indiegogo page. The duo is currently seeking $150,000 with shipment expected to begin in October 2015.

Alligator Board is a next-gen, ATSAM3X8E-based 3D printer controller

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Could the Alligator be the most advanced 3D printing board ever developed? 

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Over the last couple of years, the DIY community has experienced a proliferation of RepRap 3D printers. As the possible number of machines continues to grow, as does the need for more open-source control boards — many of which built around Atmel | SMART and AVR microcontrollers.

Adding to the growing list of 3D printer electronics is a new Indiegogo project from a Perugia, Italy startup. First seen back at Maker Faire Rome 2014, the Alligator Board was designed to serve as a complete and reliable solution for those seeking RepRap 3D printer control modules. It is based on the Atmel | SMART ATSAM3X8EA, which represents a big step towards greater computing power, compared to existing solutions driven by 8-bit MCUs. This product is well-suited for any standard 3D printer, particularly Delta models requiring more complex data computation.

The Alligator features both the native USB interface of the ARM Cortex-M3 MCU as well as a USB to UART interface. Beyond that, the control board comes with a 10/100 Ethernet interface, capable of running a web server and any kind of Internet-based application. Alligator boasts the ability to adjust the current of its motors via firmware, thereby enabling three axes to work in perfect harmony.

What’s more, the combination of its adjustable microstep size up to 1/32 and the performance of the 32-bit ARM processor ensure high-resolution prints with any architecture. Pending all goes to plan, the board will come with several expansion pack options as well, such as the Piggy Module Lite (allows for one additional extruder), the Piggy Module Plus (allows for the addition of up to three more extruders), and the Thermocouple Module. The Alligator can also be connected directly to a Raspberry Pi unit.

Other notable features include:

• External 32Mbit Flash memory (in addition to the 64Kbit EEPROM)
• 12-24Vdc power supply input
• 4x stepper motor driver, running at 1/16 or 1/32 microcstep (up to 2.5A firmware configurable current and no trimmer)
• 6x end-stop input compatible with both mechanical and optical/magnetic solution
• High current hot-end heater driver output (high-current connector)
• High current bed heater driver output (high-current connector)
• 2x precision analog input for temperature measurement with RTD (compatible with external adapter for thermocouple)
• 2x external FAN output with PWM speed control
• USB to virtual COM port interface (microUSB connector)
• Native USB port (microUSB connector)
• microSD Slot
• 10/100 Ethernet port with unique MAC address pre-programmed chip
• Expansion connector with 3 UART or 6 GPIO with firmware selectable +3V3/+5V logic levels
• 26pin Raspberry Pi-compatible expansion connector
• 3x generic PWM open drain output for general porpouse application

Interested? Head over to its official Indiegogo page, where the team is currently seeking €10,000. Initial shipments are expected to begin in June 2015.