Tag Archives: ATmega2560

3D printing a working 5-speed manual Toyota transmission

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

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!

DIY printing custom touch-sensitive displays

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The PrintScreen lets anyone print their own custom displays.

In recent years, the industry has advanced by leaps and bounds when it comes to flexible touchscreens, albeit reproducing this technology for DIY projects has been a daunting task. Have you ever wanted to devise an interactive prototype with a display, like a smart plant that can reveal incoming calls or messages? Or, how about a touch-enabled greeting card for a loved one that could depict self-created symbols? Or, perhaps a postcard that illuminates in color when triggered? Despite countless innovative ideas, affordable displays for initial mockups can be quite bulky and only come in a few sizes.

That may soon all change thanks to a group of researchers from Germany’s Saarland University who have developed a technique that could allow anyone to literally print their own custom displays, including touchscreens. The aptly-named PrintScreen has been designed to facilitate the next-generation of digital fabrication for customized flexible displays using thin-film electroluminescence (TFEL). Through the approach, an ordinary inkjet printer will pave the way for inexpensive yet rapid production of highly-customizable screens in low volume, ranging from a simple lab environment, a print shop or even at home. (It’s almost like temporary tattooing meets in-home graphic t-shirt making meets 3D printing.) The possibilities for endless as these TFEL displays can be integrated into almost every object in daily life, whether that’s affixed to paper objects, furniture, decorative accessories, bags or garments.

“We show how to print ultra-thin (120um) segmented and passive matrix displays in greyscale or multi-color on a variety of deformable and rigid substrate materials, including PET film, office paper, leather, metal, stone, and wood. The displays can have custom, unconventional 2D shapes and can be bent, rolled and folded to create 3D shapes. We contribute a systematic overview of graphical display primitives for customized displays and show how to integrate them with static print and printed electronics. Furthermore, we contribute a sensing framework, which leverages the display itself for touch sensing. To demonstrate the wide applicability of PrintScreen, we present application examples from ubiquitous, mobile and wearable computing,” the team of Simon Olberding, Michael Wessely and Jürgen Steimle writes.

How it works is relatively simple. Using a regular inkjet printer equipped with some conductive ink, Makers and designers alike can produce DIY displays from a digital template of a desired size and shape with programs such as Microsoft Word or PowerPoint and an editor like Adobe Illustrator. Making use of one of the two methods the researchers have been presenting, the template can now be printed out in about two to four hours, depending on the exact procedure, size and colors. Nevertheless, these results will be high-res displays that are just 1/10mm thick. To cover an entire standard printer page currently costs €20 ($21.69), with the most expensive part being the special ink that is required.

In order to light up a display segment, the team has crafted a controller that is tasked with applying a high-voltage, low-current AC signal between the upper and lower electrode layers. The luminance of a display segment or pixel is then controlled using pulse-width modulation (PWM), a standard method for controlling the luminance of LEDs. For mobile applications, their prototypical controller utilized a small driver IC that generates the high-voltage AC signal from a 1.0-7.0V DC power source. If a higher luminance is required, a stronger driver IC with a slightly bigger footprint can be implemented. Meanwhile, an ATmega2560 MCU triggers the optocouplers for multiplexing the high-voltage signal between display pins.

“The TFEL-specific ghosting effect in passive matrix displays can be significantly reduced by using a slightly modified controller design, thus further increasing the contrast of the matrix,” the team reveals.

“So far, nothing like this has been possible,” Olberding adds. “Displays were produced for the masses, never for one individual user.”

Printing a regular high-res display could be just the beginning, as the researchers hope PrintScreen can be used with other materials like leather, metal, stone, and wood in the future. Interested in learning more? The researchers will be exhibiting their solution at Cebit in Hanover, Germany this month. Meanwhile, you can read their entire paper here.

3D printing your own remote-controlled Mars Rover

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This DIY project is out of this world!

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.

TwinTeeth is a PCB mini-factory for electronic hobbyists

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Diyouware’s innovative PCB fabricator will give Makers the ability to create PCB prototypes right at home.

A pair of Madrid-based brothers, who you may recall from their recent DiyouPCB project, have now released the design for a new 3D printer. Diyouware’s TwinTeeth — which gets its name from the principle of moving the construction bed instead of the tool head — is best described as an open-source PCB mini-factory geared towards electronic-savvy hobbyists. It is an innovative fabricator of Arduino shield-size PCBs which will enable Makers to create circuit board prototypes right in the comfort of their own homes.

The mini-factory can perform a variety of functions, including photoengraving with a UV laser on sensitive film or pre-sensitized boards, drilling holes using any mini-rotary tool, dispensing solder paste onto SMD PCB pads, plotting circuits with a permanent pen-maker, as well as 3D printing knobs, casings, front-panels and circuits with conductive filament.

Its interchangeable tool head allows users to automate the process of most PCB fabrication stages, with its only limitation being a small Arduino shield sized workspace. The robotic device draws the PCB circuits in rastering mode much like any paper printer does, moving the laser (or the bed in their case) from one side to the other. TwinTeeth boasts auto-bed leveling, thereby giving users a flat plate with a tolerance of less than 0.01mm during the printing process.

“While traditional 3D printers or CNC machines move the tool while the working piece is fixed on the bed, TwinTeeth moves the bed while the tool is fixed. The first method is good if the tool is small and you want to make large pieces. But if the tool is heavy like a mini-rotary tool or a 3D extruder and the piece you are working on is light like a PCB, it is better to move the piece because it provides more precision and reduces vibrations,” the duo writes.

TwinTeeth is embedded with the well-known combination of an Arduino Mega 2560 (ATmega2560), a RAMPS 1.4 control board and A4988 drivers, and is powered by a trio of Nema 17 motors. Aside from that, Diyouware used modified Marlin firmware to support the multiple tools, manage and control the laser, implement the auto-focus system, print in rastering mode, and improve the buffering. A small USB camera was included to make it easier for Makers to see tiny details on high-density PCBs. According to its creators, the built-in camera is also useful to set the home position, a very important element in obtaining accuracy.

Similar to their earlier project, the Makers equipped TwinTeeth with the same PHR-803T optical pickup used in the DiyouPCB with a wavelength of 405nm. Meanwhile, Diyouware developed an entire software suite for the mini-factory, which makes for easier management and control of the machine. This program enables users to connect and disconnect via USB, select tools, move the bed, go to homing position, set the speed and Z position, calibrate the robot, stop and resume a print job, and toggle the camera view, among a number of other things.

Print area: 70mm x 80mm x 60mm
Print speed: 1200-1500mm/minute
Print resolution: 600DPI
Nozzle diameter: 0.35mm
Code: G-Code, postscript and BMP files
Connectivity: USB 2.0
Filament: 1.75mm PLA/ABS

Interested in your own PCB mini-factory? You’ll want to check out Diyouware’s entire blog post 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.

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.

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.

Video Diary: A look back at Embedded World 2015

This robot may soon 3D print objects as large as 100 cubic meters

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Artis Engineering has created a robotic arm that will soon revolutionize architecture.

While 3D printers tend to be bound by available materials, build volume and nozzle size, one Germany company is looking to change all that. In fact, a team from Artis Engineering recently conceived an idea after toying around with the concept of 3D printing: Why not use a big robot to print out even bigger objects?

Already having a gigantic CNC machine in their possession, the team’s current KUKA Quantec arm boasts a build envelope of 150 cubic meters, a 7-axis system, as well as a tool changer on its “hand” that is capable of milling, sanding, polishing, hot wire cutting, and now, 3D printing. Using the industrial gadget, Artis Engineering believes one day it will even be able to construct 3D-printed objects as large as 100 cubic meters in size.

The robot is based on an Arduino Mega 2560 (ATmega2560) and RAMPS 1.4. On the software side, the team used Rhinoceros 5, Grasshopper, KUKA|prc to make this all possible. The nozzle is equipped with two 40w heat cartridges and pair of 100k resistors, while an LCD control panel is tasked with monitoring temperatures and speed settings. Simon Lullin of Artis Engineering tells 3DPrint.com that employing a E3D v6 modified nozzle allows the team to print at high speeds, with a 0.5mm, 1.0mm and 2.5mm nozzles avoiding jamming and other problems.

“Our next goal is to perfectly synchronize the robot movements with the extruder (mainly the speed), which will require a mountain of new hardware, since we are already to the limits in terms of ‘extensions’ quantity. This is the equivalent of adding an 8th axis to our robot. This will be done in the upcoming months,” Lullin adds.

Interested? Head over to Artis Engineering’s official page here, or watch it in action below!

Aleph Objects launches the LulzBot TAZ 5 3D Printer

BS Toy is a kid-friendly 3D printer

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