3D printing

how-nascar-and-its-teams-are-embracing-3d-printing

How NASCAR and its teams are embracing 3D printing

3D printing, Cars, NASCAR, racing / /

Carbon fiber, aluminum, maybe the odd bit of titanium here or there: These are the materials we usually expect race cars to be made of. Now you can start adding thermoplastics like Ultem to the list. Additive manufacturing has become a real asset in the racer’s toolbox, although the technology has actually been used at the track longer than you might think.

“Some people think that 3D printing was invented last year,” said Fadi Abro, senior global director of automotive and mobility at Stratasys. The company recently became NASCAR’s official 3D printing partner, but it has a relationship with one of the teams—Joe Gibbs Racing—that stretches back two decades.

“Now the teams only have certain things that they can touch in the vehicle, but what that does is it makes it so that every microscopic advantage you can get out of that one tiny detail that you have control over is so meaningful to your team,” Abro said.

Currently, JGR has five printers, which it uses in a variety of applications. Some are common to other industries—additive manufacturing is a good way to quickly develop new prototypes, as well as tooling and fixtures. But the team also prints parts that go straight onto the race car, like housings, ducts, and brackets.

“These are elements that are really integral for the vehicle to be on the track. If there are changes they want to make, they throw it to the printer, it prints overnight, and you have a part that can go on a track that’s specific to that track. So that gives them a competitive advantage,” Abro said.

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Green sea turtle gets relief from “bubble butt” syndrome thanks to 3D printing

3D printing, green sea turtle, Science, Tech, wildlife / /

Two main reasons those gas pockets appear in turtles are plastics and boat strikes.

When a turtle consumes something it can’t digest—like parts of fishing nets, plastic bottles, or even rubber gloves (yes, there was a sea turtle found with a rubber glove in its intestines)—it sometimes gets stuck somewhere along its gastrointestinal tract. This, in turn, causes gases to gather there, which throws the turtle’s buoyancy out of balance.

Those gases usually gather in the parts of the gastrointestinal tract located near the rear of the turtle, so the animal is left floating bum-up at an unnatural angle. Conditions like that are sometimes curable with dietary modifications, assisted feeding, fluid therapy, and other non-invasive means to the point where afflicted animals can be safely released back into the wild. Boat strikes, on the other hand, often lead to permanent damage.

Sea turtles’ shells are tough but not tough enough to withstand a boat impact, especially when the shell gets hit by a propeller blade. This often leaves a shell deformed, with air bubbles trapped underneath it. In more severe cases, the spinal cord under the shell also gets damaged, which leads to complete or partial paralysis.“

The most popular approach to rehabilitating these injuries relies on gluing Velcro patches to the shell at carefully chosen spots and attaching weights to those patches to counteract the buoyancy caused by the air bubbles. This is a pretty labor-intensive task that has to be done repeatedly every few months for the rest of the turtle’s life. And green sea turtles can live as long as 80 years.

Charlotte swimming with the harness on.

Credit: Laura Shubel

Charlotte swimming with the harness on. Credit: Laura Shubel

Harnessing advanced manufacturing

Charlotte, as a boat strike victim with air bubbles trapped under its deformed shell, was considered non-releasable and completely dependent on human care. Since full recovery was not an option, Mystic Aquarium wanted to make everyday functioning more bearable for both the turtle and its caretakers. It got in touch with Adia, which in turn got New Balance and Formlabs onboard. Their idea was to get rid of the Velcro and replace them with a harness fitted with slots for weights.

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cheerios-effect-inspires-novel-robot-design

Cheerios effect inspires novel robot design

3D printing, active matter, Cheerios effect, fluid dynamics, Marangoni effect, Physics, robotics, Science / /

There’s a common popular science demonstration involving “soap boats,” in which liquid soap poured onto the surface of water creates a propulsive flow driven by gradients in surface tension. But it doesn’t last very long since the soapy surfactants rapidly saturate the water surface, eliminating that surface tension. Using ethanol to create similar “cocktail boats” can significantly extend the effect because the alcohol evaporates rather than saturating the water.

That simple classroom demonstration could also be used to propel tiny robotic devices across liquid surfaces to carry out various environmental or industrial tasks, according to a preprint posted to the physics arXiv. The authors also exploited the so-called “Cheerios effect” as a means of self-assembly to create clusters of tiny ethanol-powered robots.

As previously reported, those who love their Cheerios for breakfast are well acquainted with how those last few tasty little “O”s tend to clump together in the bowl: either drifting to the center or to the outer edges. The “Cheerios effect is found throughout nature, such as in grains of pollen (or, alternatively, mosquito eggs or beetles) floating on top of a pond; small coins floating in a bowl of water; or fire ants clumping together to form life-saving rafts during floods. A 2005 paper in the American Journal of Physics outlined the underlying physics, identifying the culprit as a combination of buoyancy, surface tension, and the so-called “meniscus effect.”

It all adds up to a type of capillary action. Basically, the mass of the Cheerios is insufficient to break the milk’s surface tension. But it’s enough to put a tiny dent in the surface of the milk in the bowl, such that if two Cheerios are sufficiently close, the curved surface in the liquid (meniscus) will cause them to naturally drift toward each other. The “dents” merge and the “O”s clump together. Add another Cheerio into the mix, and it, too, will follow the curvature in the milk to drift toward its fellow “O”s.

Physicists made the first direct measurements of the various forces at work in the phenomenon in 2019. And they found one extra factor underlying the Cheerios effect: The disks tilted toward each other as they drifted closer in the water. So the disks pushed harder against the water’s surface, resulting in a pushback from the liquid. That’s what leads to an increase in the attraction between the two disks.

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“impact-printing”-is-a-cement-free-alternative-to-3d-printed-structures

“Impact printing” is a cement-free alternative to 3D-printed structures

3D printing, construction, materials science, Science / /

Recently, construction company ICON announced that it is close to completing the world’s largest 3D-printed neighborhood in Georgetown, Texas. This isn’t the only 3D-printed housing project. Hundreds of 3D-printed homes are under construction in the US and Europe, and more such housing projects are in the pipeline.

There are many factors fueling the growth of 3D printing in the construction industry. It reduces the construction time; a home that could take months to build can be constructed within days or weeks with a 3D printer. Compared to traditional methods, 3D printing also reduces the amount of material that ends up as waste during construction. These advantages lead to reduced labor and material costs, making 3D printing an attractive choice for construction companies.

A team of researchers from the Swiss Federal Institute of Technology (ETH) Zurich, however, claims to have developed a robotic construction method that is even better than 3D printing. They call it impact printing, and instead of typical construction materials, it uses Earth-based materials such as sand, silt, clay, and gravel to make homes. According to the researchers, impact printing is less carbon-intensive and much more sustainable and affordable than 3D printing.

This is because Earth-based materials are abundant, recyclable, available at low costs, and can even be excavated at the construction site. “We developed a robotic tool and a method that could take common material, which is the excavated material on construction sites, and turn it back into usable building products, at low cost and efficiently, with significantly less CO2 than existing industrialized building methods, including 3D printing,” said Lauren Vasey, one of the researchers and an SNSF Bridge Fellow at ETH Zurich.

How does impact printing work?

Excavated materials can’t be used directly for construction. So before beginning the impact printing process, researchers prepare a mix of Earth-based materials that has a balance of fine and coarse particles, ensuring both ease of use and structural strength. Fine materials like clay act as a binder, helping the particles stick together, while coarser materials like sand or gravel make the mix more stable and strong. This optimized mix is designed such that it can move easily through the robotic system without getting stuck or causing blockages.

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stratasys-sues-bambu-lab-over-patents-used-widely-by-consumer-3d-printers

Stratasys sues Bambu Lab over patents used widely by consumer 3D printers

3D printing, bambu lab, Stratasys, Tech / /

Patent protections pushed for proprietary processes —

Heated platforms and purge towers are among Stratasys’ infringement claims.

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Bambu Lab A1, with three filament spools connected by circular loops off to the right.

Enlarge / The Bambu Lab A1, complete with heated build platform.

Bambu Lab

A patent lawsuit filed by one of 3D printing’s most established firms against a consumer-focused upstart could have a big impact on the wider 3D-printing scene.

In two complaints, (1, 2, PDF) filed in the Eastern District of Texas, Marshall Division, against six entities related to Bambu Lab, Stratasys alleges that Bambu Lab infringed upon 10 patents that it owns, some through subsidiaries like Makerbot (acquired in 2013). Among the patents cited are US9421713B2, “Additive manufacturing method for printing three-dimensional parts with purge towers,” and US9592660B2, “Heated build platform and system for three-dimensional printing methods.”

There are not many, if any, 3D printers sold to consumers that do not have a heated bed, which prevents the first layers of a model from cooling during printing and potentially shrinking and warping the model. “Purge towers” (or “prime towers” in Bambu’s parlance) allow for multicolor printing by providing a place for the filament remaining in a nozzle to be extracted and prevent bleed-over between colors. Stratasys’ infringement claims also target some fundamental technologies around force detection and fused deposition modeling (FDM) that, like purge towers, are used by other 3D-printer makers that target entry-level and intermediate 3D-printing enthusiasts.

Bambu Lab launched onto the 3D-printing scene in 2022, quickly picking up market share in the entry-level and enthusiast space, in part due to its relatively fast multicolor printing. It hasn’t had an entirely smooth path to its market share, with a cloud-based force printing fiasco in the summer of 2023 and a recall of its popular A1 printer for heat issues earlier this year.

Stratasys, by contrast, has been working in 3D printing since 1988, and its products are used more often in manufacturing and commercial prototyping. Its 3D printers were part of how General Motors pivoted to making face shields and ventilators during the COVID-19 pandemic. Its acquisition of MakerBot led to layoffs two years in and eventually a spin-off merger with Ultimaker, but Stratasys retained MakerBot’s patents.

Another patent lawsuit filed by a larger prototyping firm against a smaller semi-competitor was settled in 2014. 3D Systems sued Formlabs in 2012 over patents regarding laser-based stereolithography. That suit ended with Formlabs agreeing to pay an 8 percent royalty on all sales to 3D Systems. Stratasys had also previously sued another smaller-scale printing firm, Afinia, in 2013, although that case eventually failed.

Listing image by Bambu Lab

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“rasti-computer”-is-a-detailed-grid-compass-tribute-made-from-framework-innards

“Rasti Computer” is a detailed GRiD Compass tribute made from Framework innards

3D printing, computer history, grid compass, grid systems corp, laptop design, mechanical keyboards, Tech / /

But can it play Pitfall!? —

It’s a custom keyboard, an artfully dinged-up case, and a wonderful throwback.

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Penk Chen's Rasti Computer

Enlarge / Penk Chen’s Rasti Computer, built with 3D printing, Framework laptop internals, and a deep love for the first laptop that went to space.

If I had to figure out what to do with the insides of a Framework 13 laptop I had lying around after today, I might not turn it into a strange but compelling “Slabtop” this time.

No, I think that, having seen Penk Chen’s remarkable project to fit Framework parts into a kind of modern restyling of the Grid Compass laptop, I would have to wait until Chen posts detailed build instructions for this project… and until I had a 3D printer… and could gather the custom mechanical keyboard parts. Sure, that’s a lot harder, but it’s hard to put a price on drawing unnecessary attention to yourself while you chonk away on your faux-used future laptop.

The Rasti Computer, which Chen writes is “derived from the German compound word ‘Rasterrahmen’ (grid + framework),” has at its core the mainboard, battery, and antennae from the highly modular and repairable first-generation Framework laptop. It takes input from the custom keyboard Chen designed for the chassis, with custom PCB and 3D-printed keycaps and case. It sends images to a 10.4-inch QLED 1600×720 display, and it all fits inside a bevy of 3D-printed pieces with some fairly standard hex-head bolts. Oh, and the hinges from a 2012 13-inch MacBook pro, though that’s possibly negotiable.

  • Rear view of the Rasti Computer, with “a touch of silver dry brushing [that] added the beat-up metal look.”

  • Semi-exploded view of the Rasti Computer.

  • You can, of course, run Windows on this device, if you like. But it might feel dissonant to put so much custom work in to run a stock OS.

Chen’s project derives from, and pays tribute to, the Grid Compass (styled “GRiD” by its maker, GRiD Systems Corp.). The Compass was probably (again, probably) the first clamshell-style laptop made. It saw use by NASA’s Space Shuttle program, as well as by military and other entities needing a laptop that was both compact and throw-it-at-a-wall durable. It had 256KB of memory by default (less than half the amount Bill Gates didn’t say you should ever need), a 320×240 pixel screen, and an Intel 8086 processor. Some models contained a 1,200bps modem. It cost more than $8,000 in 1982, or almost $25,000 today.

We have it on good word from some resident vintage computer collectors that the Compass remains a rare and expensive item to get. Rebuilding a Framework mainboard into a modern-day Grid-like doesn’t seem particularly cheap, depending on your 3D printer setup, or lack thereof. Nor is it likely to be easy, given a glimpse at how it goes together. But it will give you a unique portable and conversation piece, one that runs programs beyond Grid-OS.

You can read more about the Grid Compass at Cooper Hewitt, the firm where Compass designer Bill Moggridge worked as design director from 2010 until his 2011 passing. If you remember bubble memory, it’s a dip back into that genial trauma. Hackaday, where we first saw the Rasti project, wrote up a similarly Compass-inspired laptop, the GRIZ Sextant, with a Raspberry Pi at its core.

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