2016: Stories Made in America

Over the past 3 years our company and community have seen a ton of changes. Through a shared vision to make industrial 3D printing more accessible, our team rallied from multiple locations across the US, scaled our idea in Chile, and later established headquarters in Texas. Since launching in Santiago, we’ve opened two offices in Houston & Austin, which is complemented by a remote sales presence in San Francisco.  Although our team is centralizing operations in the USA, re:3D remains thankful to our Chilean roots and the $40K in funding that gave us the opportunity to make an idea a reality.

We also recognize that through our 2 crowdfunding campaigns that Gigabot’s reach has expanded to new frontiers around the world.  We will always attribute our 2013 Kickstarter success to the thoughtful insight, organization, and advertising enabled through the Start-Up Chile program. However, since leaving Santiago after 7 months, customers and suppliers throughout both North America & South America have emerged in Texas and beyond.

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Visiting Mkerstudio MX / Impresión 3D Gigabot & team in Mexico City

With this in mind, we’ve invested considerable effort into analyzing how our community and resources have evolved over three years. For example, you can view a breakdown of where our customers are located in the map on our website. In our examination of where re:3D has impact, we’ve discovered that over 80% of the materials we source for Gigabot, 100% of our labor, and 78% of Gigabots in the field are in North or South America.

In 2014 & 2015 we also sent out surveys to our community, interviewed over 50 customers in person and attended events throughout the US that allowed us to engage with up to 500,000 people to hear your thoughts on human-scale 3D printing. Undeniably the biggest request of all of our road-trips was that we share stories of our personal adventures printing huge and those of the 300+ Gigabots worldwide. We’ve also had a strong demand for a more robust forum, which Mike is hoping to launch next month- more to come!

As we’re still proudly bootstrapping, it struck us that we have an enormous opportunity to immediately leverage the dense community around us to photograph, video, and document the customers we encounter. We’ve devised a list of questions to capture information we’re told you want to hear:

  • Longest print
  • Biggest print
  • Application/ reason for printing huge
  • Materials tested
  • Favorite print
  • Challenges, feedback and requests
  • Cost and Time Savings
  • Your Gigabot Workspace
  • Your workflow

We hope this is only the beginning of building stronger relationships with all of our customers personally. We aspire to eventually meet all our customers, and are focusing first on sharing the stories of those closest to our operations first. We’re hoping to socially engineer affordable ways to ultimately canvas the globe, but for the short term we’d like to intentionally focus locally.

route66

With this in mind, we’re pleased to announce our Made in America campaign. Each week, beginning next week, you can anticipate a blog, video and photographs that share the experiences of pioneers like you, who #dreambigprinthuge as we hit the road to engage with our American clientele.

To ensure we are fulfilling your requests for more curated content, we’d love your input. What questions would you like us to ask customers? Who would you like us to visit? Are there any National Parks we should check out enroute? We welcome your suggestions at marketing@re3d.org as we embark on an adventure to explore what’s being #madeinamerica on Gigabot.

Happy Printing!
~Samantha & Katy

re: 3D Printing Furniture

My first attempt at 3d printing furniture went pretty well. The stool I designed  and later printed on the Gigabot ended up on-stage with Samantha Snabes, Co-Founder of re:3D, presenting to 5,000+ attendees at Web Summit in Ireland. Somehow along the way, Prime Minister Enda Kenny struck a pose with it. What an honor!

re:3D won 2nd place out of the Beta Pitch group and the 3D printed stool made it into several of the pictures that ensued; very exciting to watch the twitter streams.

For my next project, the goal was to create a piece that combined 3d printing with existing materials. I had been saving a slab of walnut purchased from eBay and thought, why not turn it into a bench? It was a pleasant challenge designing the base to follow the feel and flow of the live-edge slab. I wanted technology and nature to seemingly merge. It’s a beautiful slab and I needed to do it justice! There’s a great book out there about how loads are distributed in nature which helped to inspire the bench; it’s called “Design in Nature: Learning from Trees” by Claus Mattheck.

benchinprocess

The piece required a two-part print due to the large size so it was split it at an inconspicuous angle down the middle. The base was designed with pocket-screw holes and once lined up, was secured to the live-edge slab with pocket-screws. While the print itself was structurally sound, I coated the entire bench in clear epoxy just for some added strength. The gloss finish on the base was sanded back down to satin using 200 grit sandpaper. The indicators on the bench represented spots that I had missed with epoxy; they pointed out where I had to touch up on a second coat.

I was very pleased with the result and honored to have been included in Big Medium’s Austin East alongside many other great artworks.  Even Google’s self driving car stopped by to see what’s up. I think they look good together.

Mike’s 3D printed bench is featured at the Big Medium East Austin Studio Tour (self-driving car for scale:)

Having access to a Gigabot has opened up so many more doors due to it’s scale and precision. Can’t wait to start my next project which I will be sure to post about in the next couple of months.

Happy Printing!

Mike Battaglia

Blog Post Author

re: thinking Buoyancy – Hanging 10 on a 4pc PLA Surfboard

The Big Idea

Like most start-ups intent on exploring the intersection of tech and sheer awesomeness, the vision to 3D print a surfboard was cast over beer, at a co-working space (Capital Factory), subsequent to a lack of sleep. Disregard the fact the nobody physically present at our Q2 re:treat had actually surfed, we were still proudly penny-pinching, and had few Gigabots available for extended personal print marathons. Instead, Marketing Co-Leads Katy and I corroborated with our Gigabot Ambassadors Rebecca, Morgan and Todd to develop a list of “use cases” to demonstrate functional 3D printing to be executed by a cadre of summer interns. Buoyancy made the shortlist, and a surfboard was an obvious case study.

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Q2 re:treat with @Marvin_3D

Our leadership team cultivated job descriptions, which Katy hosted under a tab she designed at re3d.org/careers. The response to our unpaid internship postings were higher than anticipated, and ultimately we selected Akshay as our 2015 Design Intern focused on 3D Printing a surfboard. Despite still being in High School, his confidence, professionalism and experience modeling through his high school FIRST Robotics team convinced me he was up for the challenge. He also had a glowing recommendation from his coach Norman.

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Brainstorming over Amy's Ice Cream w/Matthew, Annabelle & Akshay

The Design

Within just a couple weeks of on-boarding and conducting research on surfboard 3D printing, Akshay presented his concept. He had identified others who had been successful including a Father & Son, as well as professional 3D printed surfboard companies. Those that have gone before had done an amazing job curating surfboard designs that truly exhibit the benefits of 3D printing, whether it be enabling custom designs or geometries not easily produced in traditional manufacturing. However, due to the small volume of many affordable printers, we noticed multiple parts were required to later be stitched together like a jigsaw puzzle or they depended on expensive SLS printers to produce a monocoque body.

Endless Sinter SLS Surfboards
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ABS Jigsaw Surfboard

Knowing that we had the benefit of leveraging one of the largest affordable industrial printers at our disposal, we set out with Akshay to investigate if we could make a FFF (Fused Filament Fabrication) design in the fewest pieces possible. We also wanted to challenge notions of material strength. Akshay’ s research unveiled that our desktop 3D printing peers used ABS, a plastic despised by many for its stinky smell during printing, but stronger than it’s as readily accessible counterpart PLA. Being bootstrapped, we work from a small office, so we decided to use PLA to print our board to see if the sweet smelling, accessible filament could support the weight of a human in the ocean repeatedly, thus challenging the assumptions of PLA’s limited value in functional, life-sized 3D prints. You see, we didn’t choose PLA because we thought it SHOULD be the material of choice, rather we wondered if it  COULD be used in a functional application.

And if it worked (even limitedly), we wondered…..what other applications would you and other members of the open-source community cultivate that could expand on our buoyancy experiment?

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Akshay dialed into Katy's Design Tag

To develop the initial concept, Akshay paired up with our Summer Stand-up Paddleboard Design Intern Evan, who was also exploring the possibility of supporting a load on water.  During Katy’s Thursday Design meetings they evaluated each other’s models in Solidworks, discussed stress points, and analyzed the best way to join components. They also ran a series of experiments to deduce not only if PLA floated, but also if it could be water tight. While they initially pursued similar concepts involving a series of rods conjoining dense pieces, they later opted for separate methods. The stand-up paddleboard included a series of hollow segments, filled with Great Stuff, bound with Gorilla Glue, and fiber wrapped.  The surfboard, Akshay decided, would be four, 6% honeycomb-filled segments held together by a series of 50% infill 3D printed bricks. Like Evan, his instrument of choice for sealant included copious amounts of Gorilla Glue.

This was our first foray into a “formalized” summer intern program and the weeks flew by. We learned a ton about setting deadlines, procurement delays, accounting for R&D or marketing inventory in our budgeting & bookkeeping, and how to better mitigate bottlenecks in Gigabot availability for multiple, multi-day crazy prints.

As June turned to July, the scaled-models and sketches transformed to full-scale experiments. Katy’s design meetings became increasingly important as the group collected feedback from the team and data from real-world tests which influenced model adjustments.

Fin Design

Throughout the summer, the surfboard fin underwent as significant an evolution as our scaling team using input from experts, the open source community, and our own failures. Askhay’s first design included two tabs to be glued into the frame, which floated and appeared to have the infill & form required to be successful based on our initial tests. However, after delving into the minutia of surfboard design, Akshay discovered that most fins are supported via a T-slot in the surfboard body. For this reason, he later designed a fin to be inserted into a groove. Unfortunately, we later learned we needed screws holes on either side to mount into the T- nuts. Mike responded to the challenge and mocked the final design, which included the re:3D logo as well as fixtures for the screws to mount into Akshay’s conceived T-nut slot. Mike also suggested that the fin be printed in black to complement Akshay’s silver board.

Final Construction

By the time the 1.5 long week print was ready for the final piece, July had morphed into August and Akshay had to return to high school.  A couple of weeks into September we attempted to resume the project and he modeled the 4th piece using feedback I relayed remotely. Despite my best efforts, the measurements provided were a little off and the 4th piece wouldn’t align. Both Jeric and Mike supported a redesign and during a long weekend, Mike ultimately generated the final component to Akshay’s vision as well as some much needed “deckholes” our research revealed was required for a surfboard leash, which we purchased from SUP ATX as we figured the extra length on stand-up paddleboard leashes offered might be needed later. With the body complete, we encountered a new set of challenges. During a commute between our Houston and Austin offices, our almost finished 3d printed surfboard took a tumble on our high-strength 3D printed bicycle designed by Patrick, leaving a rather impressive hole. Determined to make it work, I filled the  crevice with silicon prior to using Bondo to level the uneven Gorilla Glue texture.

Jeric did a stellar job capturing a time-lapse of the final piece!

The Test

While touring an untested BETA experiment 7000 miles might sound crazy, for our team it made perfect sense. We had won 2nd place at Websummit last year for pitching our vision to 3D print from trash and 1st at their US event, Collision which granted us free passes for our team to return to Ireland. It therefore seemed natural to transport a untested ambitious print across the sea in front of thousands of media & startups in the name of challenging assumptions around 3D printing.  Upon reflection on the flight to Ireland, it became evident that our success to date and win at Collision, was truly a testament to community support. For this reason, we decided it would be an honor to recruit as many stickers as possible from Web Summit attendees willing to affix their brand to our untested experiment. We humbly collected 150+ logos, including StickerMule, a popular vendor.

Shaun the Sheep

If you followed us or Web Summit/Surf Summit on social media in the past month, you might be a little confused by the multiple references to sheep, Shaun, Gigabot, Irish shepherdesses, and surfing sheep.

The idea to 3D Print Shaun the Sheep was conceived by a female Sheppard & blanket maker named Suzanna of Zwartbles Ireland. Suzanna maintains an active community via social media (@ZwartblesIE) and during our flight over suggested #Gigabot could #3dprint a #sheep in #ireland. The initial Tweet inspired a lively conversation and I found myself Googling open-source sheep stls while flying past Iceland. When Katy & I landed, Matthew suggested this Wooly Sheep by pmoews  to test out on Gigabot, which had been created using a 123D Catch, now ReCap Pro, scan of a garden ornament. Three days of continuous sheep printing and ewe puns soon began. Katy christened the first small-scale sheep as Dolly before making a larger 14 hour sheep. The downside of running large prints is that Gigabot has to work throughout the night. The 3rd shift security team had the pleasure of watching our biggest sheep complete and informed us one morning that they had named him Shaun. It wasn’t until later the next day that we learned Shaun referred to a popular show titled Shaun the Sheep. Shaun quickly garnered a small fan club, and we decided to take him to Sligo, Ireland for Surf Summit as the prize for the 1st surfer to successfully catch a wave on the surfboard.

Surf Summit: The Moment of Truth

As soon as Web Summit concluded, we crated Gigabot for the return to Texas, them scrambled to pack our bags, the surfboard, and sheep for the bus ride to Sligo, the host of Surf Summit. Surf Summit is an incredible post-summit event to cultivate friendships while experiencing the Irish countryside. As the video reveals, it was a breathtaking experience- our only regret being Matthew couldn’t attend in leu of a customer he committed to visiting in the UK. As complete surf novices, Surf Summit provided the perfect proving group for the surfboard test as several surf pros were in attendance to share their experience & wet suits!

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Shaun, Katy, the surfboard & I board the bus

Prior to surfing, we attended the kickoff festivities and allowed Shaun to circulate with the attendees before (he hoped) he would be gifted to a deserving surfer.

Session 1

The next morning we loaded the board, attached the fin, crossed our fingers for good luck and took off to Streedagh Beach. Upon arrival, we were greeted by a team of instructors from Surf World Bundoran, who helped us wax the board and taught birthday girl Katy & I to surf for our first time. The experience was unforgettable.

As our lesson concluded, SurfWorld Instructor Tony volunteered to take our stickered print out on the water. We grabbed our cameras and huddled with our new start-up friends from The Outdoor Journal to capture a mini photo shoot before take-off. The tension was palpable and we all lingered a moment discussing the project, for fear that the board was soon break or worse, sink, taking with it the evidence of so many peers who had supported the endeavor.

Tony proceeded with caution, first testing the buoyancy in shallow waters near the beach, then gradually paddling out further. After a few minutes, he headed out to see if he could catch a break. It wasn’t long before a series of rolling waves emerged and, as luck would have it, he was able to ride one in!

After Tony broke the seal, two other brave instructors also offered to take the surfboard out, despite loosing a fin!

Session 2

Wanting to optimize our wave catching, we headed back to the hotel, then caught a cab to Strandhill beach to join another surf instruction course after lunch. There we met the crew at iSurfIreland who agreed to try her out and broke personal records in distance traveled (which complicated picture taking)! Four surfers tested the board, and gave us valuable improvement ideas.

Feedback

In total 7 instructors braved the board. The advice we received was pretty consistent:

  • The current board is too thick
    • In the future it should be thinner and consideration should be given to reducing weight
  • The curve is not ideal
    • The board should bow more at the top
  • We could have better leveraged the benefit of 3D printing
    • The current design mirrors current manufacturing aesthetics and could have been sexier
    • Surfers appreciate custom features (holds for cameras, grips, personalized lettering)
  • The absence of a durable fin made it hard to maneuver
    • I should have printed the fin flat so it couldn’t delaminate, and/or used honeycomb for more density
  • A three or multiple fin design would be ideal
    • Ours had only a single fin
  • Stickers made the board more slick, albeit cool!
  • Everyone seems optimistic that 3D printed has great potential in watersports, especially wakeboards and body boards
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Photo by Katy Jeremko

One Month Later

Currently the surfboard resides in our Austin office. What began as an idea, transformed into a internship, that took us 7000mi and introduced us to new friends around the world. As we reflect on the people we met through Akshay, sheep printing, sticker collecting, and trial by water we are struck by the creativity & vision that the community shared. We hope this is the first of many use cases that will expand our perspective on what is possible through affordable, life – size 3D printing. We welcome your ideas on where we go from here!

Happy Printing,

Samantha snabes

Blog Post Author

~Special Thanks to: our Intern Akshay, Coach Norman, Mike Battaglia, Jeric Bautista, the makers of Gorilla Glue, SUP ATX, WakeBoard Graphics Austin, Sail & Ski Austin, to the ENTIRE Web Summit/ Surf Summit Staff, all the StartUps that shared their stickers, The Outdoor Journal, The city of Sligo, IDA Ireland for the rad T shirts, isurfIreland, Surf World, and our staff who all had a hand in this crazy adventure!

~~We're still catching up on post-summit sleep. It's possible I missed a credit or left a typo. Feel free to submit additional pictures, corrections, comments, or questions to @samanthasnabes

My Great Big Gigabot Summer at re:3D

While applying for summer internships last spring, I did not imagine I would be as involved or as integrated into the company team as I was during my time at re:3D. This past summer, I got to explore and expand upon some of my own passions while taking on the role as the project lead for re:3D’s Great Big Gigabot Giveaway.

As I read the job description for film/social media intern position, I was excited that I would be able further explore my interest in creating videos. This is exactly what I did! This summer I worked with a video editing software called Adobe Premiere Pro CC for re:3D. Having prior experience with only Apple’s iMovie and Windows Movie Maker, I was eager to learn a more versatile software. My role as a summer intern soon evolved to specifically revolve around the second giveaway competition. re:3D was approaching the milestone of shipping out its 300th Gigabot, and the tradition of celebrating such a memorable moment is to give back to the community by giving away one of their industrial 3D printers to some with a vision to make a difference through 3D printing. You watch this year’s announcement video that I developed to announce the contest here.

I had the opportunity to work closely with Samantha and so many other amazing individuals through helping organize this competition. We recruited several amazing judges and in-kind sponsors, and I was astounded by the amount of support we got to help make this project possible. Even members of Tunapanda, the recipient of last year’s giveaway Gigabot, were happy to judge and sponsor this year’s competition. Check out all of this year’s judges and sponsors here if you haven’t already!

Pre-planning the competition with Jones Dilworth
Pre-planning the competition with JDI

Out of all the things I experienced during my summer at re:3D, my favorite was probably being one of the first to see the applicant submissions for the competition. Even though the applicants were very diverse in their backgrounds and ideas, I realized that they all had one key aspect in common: the passion to positively influence their communities. One thing I wish I could go back and change about the competition structure is the length of the submission period. We had several people with great ideas start their applications, but not as many people complete them. It was awesome to see all the people who put forth the effort to create a video to enter into the contest.  We also were honored to see the story posted on several industry blogs: 3Dprinting Industry, 3Dprint.com, and Techfortrade.

The purpose of the Great Big Gigabot Giveaway was to give back to the community by supporting an idea to impact society, and well, the 3D printing community certainly has a far reach. The recipient of the 300th Gigabot is Tochukwu, the man who is behind 3D Nigeria. This project plans to inspire a new generation of makers in tertiary institutions in Nigeria. Tochukwu and his team of makers hope to unleash the creative potential of these individuals and create value for consumers.

A big congratulations again to the winner and the runners up, Ability Maker and The Creator Program. You can view the incredible ideas of the entrants in the winner announcement video here or below:

All-in-all, I learned a lot this summer at re:3D from being directly involved on a project I could call my own. More importantly, however, I can definitely say that the best take-away was meeting such extraordinary people and cultivating those relationships. Looking forward to working on another project with re:3D in the future!

Sanchana Vasikaran

Blog Post Author

@v_sanchana

Free 3D Printable of the Week: iPhone 6 Plus VR Headset

Last Month we had the honor of seeing @MikeBattaglia featured in 3DPrinting Industry! Below is a re-post of the content by Michael Molitch-Hou.

~FRI, AUGUST 14, 2015 · FREE 3D PRINTABLE OF THE WEEK, VR

Many Google Cardboard headsets, and variations thereof, just don’t quite fit iPhones properly. And they certainly don’t fit the new iPhone 6 Plus. So, unless you’re planning on shelling out for a complete 3D scanner/VR system from Occipital, re:3D, the makers of the large format Gigabot 3D printer, has designed a 3D printable headset.

free-3D-printable-VR-headset

re:3D designer Mike Battaglia instructs you to, “Take your lenses and magnets from Google cardboard and port them over to this way sexier headset! Print with a raft, no support.” So, what are you waiting for?

~Michael Molitch-Hou

About the Author: Michael Molitch-Hou is Editor-In Chief of 3D Printing Industry and the founder of The Reality™ Institute, a service institute dedicated to determining what’s real and what’s not so that you don’t have to. He is a graduate of the MFA Critical Studies & Writing Program at CalArts, and a firm advocate of world peace. Michael currently resides in San Pedro with his magical wife, Danielle.

Mike Battaglia

Blog Post Author

@mikebattaglia

3D Printed Recorder: Flute-Folk Whistle

Pranathi Peri is developing a set of 3D printed, playable musical instruments for her summer internship. In her own words, she describes her design process:

When I was 5 years old, I remember walking into the music store, and immediately seeing hundreds of different instruments that were all foreign to me at the time. I had learnt a bit about music Here before visiting the music store but I didn’t have much knowledge about pianos. My Mother talked to the manager about purchasing a piano, while I explored all of the different instruments, getting a feel for each one individually. In that moment, I decided that instruments were something that I really found a natural passion for. This is the reason why I now play not only the piano, but also the guitar, and violin, and am self-taught in various other instruments as well. For this reason, I jumped at the opportunity to 3D print instruments.

As I explored the idea of designing my first 3D printed instrument, I had many questions and doubts. How do I alter the size to compensate for the material? Will the characteristics of a normally constructed instrument translate directly to that of a 3D printed instrument? Would it even work?

I took all of those questions into consideration, and through extensive research, I decided to design and print the most simple, straight forward instrument possible: a recorder. 

Recorders date back to the early 18th century, and are still used today in elementary schools all over the nation. Do you remember playing “Hot Cross Buns” and “Mary Had a Little Lamb” on that small plastic flute? There’s your classic recorder. Traditional medieval and baroque recorders are carved out of wood by a skilled luthier, but are now mass produced in factories, usually being made out of a plastic alloy. 3D printing an instrument, is in a way, a bridge between traditional production, and factory production. It allows for the precision and quality produced by a luthier to be expressed, while truncating the large time and labor-intensive factors that factory production targets.

I looked at how the acoustics transmitted inside the recorder, and how various holes produced different tones, and decided that I would mesh these characteristics with that of a whistle. I was also inspired by the recorder design of Cymon on thingiverse.com. (http://www.thingiverse.com/thing:12301)

The final product that I created, is a combination of a recorder, folk whistle, and flute. Its tones and overall shape come from the recorder, the fact that it’s produced in one piece only (thanks to the GigaBot) and its various hole sizes are derived from the folk whistle, and its long, slender form, originates from the flute.

It works fairly well, being able to play “Hot Cross Buns,” and “Jingle Bells,” but with a few small upgrades and changes, it will be able to play louder, produce a more clear tone, and have a wider range of tone, as opposed to the more muffled, and slightly flat tone it produces now.

3D printing instruments like recorders, violins, guitars, and other instruments can be very helpful to our musical society. It allows for instruments that must be created one at a time by skilled luthiers, to be created by these precise 3D printers, while still being able to produce the same great sound. The amount of potential associated with the ability to 3D print instruments at home is unmeasurable. Not only does it reduce the amount of time taken to produce, (being built by a luthier versus being 3D printed) but it also opens the doors to a revolution in instrument material. Materials that could not be used by a luthier to make an instrument could be integrated into a 3D printer to create new, unique sounds that a traditionally produced instrument is not capable of making.

I learned, while creating this recorder, that there are many different variables and outside factors that go into making an instrument. Rather than tackling them all at once, it is both easier, and more efficient to start with implementing the most basic characteristics, and then working your way up.

Because of these lessons I learned, I’ve ventured into designing and printing a ukulele more confidently, and having less questions and doubts than before. 🙂

Pranathi’s Research Links:

I’d love to hear your feedback!

Pranathi peri

Blog Post Author

@PranathiPeri

How to take your Gigabot Off-the-Grid

One of our values at re:3D is to provide 3D printing technologies to communities around the globe, many of whom don’t have the resources we take for granted.  Access to plastic feedstock, a consistent power infrastructure, and reliable shipping services have always been a requirement to play in the 3D printing space. We want to change that. One of the microsteps in this direction is to find other ways to power our 3D printer, the Gigabot, while still allowing multi-hour (and sometimes multi-day) prints to emerge from our 600mm X 600mm (2ft X 2 ft) build platform.

I started experimenting this past week using a 40W solar panel and a car battery, and had some success printing a small test print. I’ve gotten some questions since then and wanted to explain a little more about my setup, and also find out if there were any other (successful or not) attempts to take YOUR 3D printer off-the-grid.

MY SETUP

Our Gigabot takes 110V or 220V mains power, but then immediately feeds that to a 24V power supply to power the motors, hot end, sensors, USB comm port, and display. The only part that makes use of the mains power is the heated bed (the one that can fry an egg).  Since using PLA as an input material usually eliminates the need for a heated bed, I started there.

Disconnecting the power supply completely, I wired the 12V battery directly to our controller board and internal cooling fan. I later learned that this cooling fan was a great audible indicator of voltage levels – but more on that later.  12V is at the very low end of what our controller board can take in, but the real question was how long could it print for?

THE PHYSICS

I like to equate electricity to water coming out of a hose (like in this great tutorial from SparkFun), so to follow that analogy, I had to figure out if I could hold enough “water pressure” (voltage) to keep the controller alive, a large enough “holding tank” (car battery) to last for the entire print, while using solar panels to add enough “water” (power) to the system during the print.

After testing with a multimeter, I saw that the Gigabot draws about 5A at the most, and less than an Amp when idle (to keep the controller and comms alive), and on average about 3 or 4 Amps while printing (since the heating element cycles to maintain a constant temperature). Judging by the rating on my car battery of 70 Amp-hours, I could count on about 14 hours of power.

I should add that we often exchange Amps and Watts freely when comparing power levels. They are only interchangeable if the volts of the system remain constant (12V or 24V for Gigabot, 120V for USA Mains, etc.), since Power (Watts) = Current (Amps) * Voltage (Volts).

Or per the above analogy: Ability to Remove Mud From Car = Size of Hose * Water Pressure.

THE EXPERIENCE

The solar panel I bought from Fry’s was impressive, but at 40W I know it wouldn’t get to the levels I needed, and I could only afford to experiment with one. Plus, pausing a print when the sun goes behind a cloud just isn’t practical, since it would leave many marks of semi-melted plastic along the way, and the stepper motors would lose their homing location. I knew that the final solution would at least rely on some battery power.

We all know what happens when our car battery is suffering when you try to start it: the lights get dim, you turn off everything electrical, and pray that it turns over and you can get home that night. Instead of a gasoline powered motor and alternator to keep the battery alive, I had a solar panel – and it had to last the entire print. So I had some questions – and like any former space station flight controller, I took lots of data.

THE QUESTIONS

Would 12V be enough to power a system that we have been used to operating at 24V since the very early days? Would my Gigabot’s hotend pull down the stepper motors too far on battery power and affect the success of the print? Could I use all of the available power in the car battery to make a large enough object without any transient errors? Could I turn on and off the solar panel or battery charger during a print without interrupting it?

THE RESULTS

At first things looked (and sounded) gloomy. The first few attempts failed, and it seemed that the battery just didn’t have enough power to drive the hotend, motors, and electronics to keep the voltage levels high enough. Even the fan noise sounded sickly – a lot worse then when I had it set up without the multimeter.

firstpicoffthegrid

The multimeter! That was it!!

I had wired my multimeter in line with the positive line off the battery to read a super accurate space-rated amp-draw during the entire print. I had wanted to measure exactly how much was going in and out of the solar panel, and the battery. The measurement itself was actually resisting the flow of electricity (the equivalent of bending the water hose to hear if water is rushing past the fold in the line). Once I removed the multimeter and tracked only the voltage across the battery terminals, I was able to get over 13 hours of continuous printing time out of my Gigabot – enough to print this 300mm (12-inch) tall vase! Here are the (manually entered) data points for that one:

The solar panels are pretty straightforward, and work very similar to the battery charger I plug into the wall, so for the purposes of my experimentation in the garage, I’m alternating printing on battery power with a charger on/off, solar panel connected/disconnected, at varying voltage levels of the battery. I think I have found the limits, since my prints start failing at just about 11V on the battery now.

Also, ever since I automated my data taking process, I get much more sleep at once, without needing to wake up for data takes with pen and paper (and help from Google Sheets). Check out the new and improved version with a little help from plotly!

An interesting part of this method of gathering data is that you can start to see the cycling of the cartridge heater very clearly as the extra current draw pulls the battery voltage down each time the hotend is full-on. This will be useful in tweaking my PID values no doubt, and could also lead to better methods of insulating the hotend so it doesn’t need to heat up as much, thereby saving valuable amp-hours!

NEXT STEPS

Clearly there is a little more work to do before we have a brownout-proof or solar-ready Gigabot out of the box, but I think these experiments prove it’s within the realm of possibility to create 3D objects anywhere – given a robust enough printer, and a light bulb’s worth of energy and imagination.

Chris Gerty

Blog Post Author

Turn Your Logo into 3D Printed Awesomeness

It’s one thing to have your company’s or school’s logo on a T-shirt, but have you ever wanted to make a 3D model of your logo to use as a keychain, business card, or maybe a coffee table? In this blog I’ll show you the process I use, and how (kind of) simple it can be. No, really, I’ll keep things basic and in all cases rely on much smarter people and tools than I could muster up myself. 

Of course if you have any other suggestions for a better method, corrections/clarification to this method, or are skilled in the “complicated” ways of doing this, please leave comments on the cross-post on our Facebook page or G+ Community.

So, let’s get started.

Step 1: Find a logo

Say you have a really cool company and one of your co-founders is a ninja of design. Chances are you have a great 2D logo that is just screaming for access to that 3rd dimension. In this example, we’ll use Katy’s re:3D logo. Make sure you have your file saved locally as a .png, .jpg, .gif, or .bmp. These filenames are of the “raster” variety (think pixels on a TV). The clearer the image the better, because we’re about to convert these raster files to vector files (think connect-the-dots meets color-by-number).

Step 2: Convert your image to a vector format.

There are a bunch of ways to do this in expensive (and probably inexpensive) image processing packages, but I found a pretty solid online converter that does enough to get us by without knowing anything about layers and paintbrushes. Go to http://image.online-convert.com/convert-to-svg and upload your image file where it says “Upload your image you want to convert to SVG:”. Select the “Monochrome” checkbox to help prevent it from getting too confused. Click on “Convert File”. Your .svg version should download to your default directory. Note where this is since you’ll need it in Step 5.

Step 3: Create a new 3D model using Tinkercad.

Go to https://tinkercad.com/ and sign up for a free account. I guarantee you’ll use it again. Once you have an account, and have either skipped or run through the actually pretty useful tutorials, start with a fresh palette using the “Create a Design” button from the dashboard.

Step 4 (optional): Customize your palette.

You’ll be presented with a blank grid, and a random name will be assigned, like Ominous Seapod or something. Click on the “Design” menu, and then “Properties”. Change the name to “3D Logo” or something similar and more original. Choose the visibility and license you want, and then save changes.

Step 5: Import your vector file.

On the right side of the screen you should see an “Import” section. If it’s not already expanded, click on the triangle to do so. Then click “Choose File” and point it to your .svg file created in step 2.

Step 6: Genesis!

Here’s where you need to experiment a bit. Depending on how much resolution you kept in your original file, the model may completely overwhelm the design space. For now, choose values of 5mm for the height and 20% for the scale. This will make sure that you can at least tell if your model ended up on the canvas (and it doesn’t just cover the entire field of view with a single face. For rescaling, if you want to maintain the 5mm height, it’s much easier to just re-import at a different scale, rather than scale with the Tinkercad tools on an over/undersized model.

Step 7: Tweak your model from within Tinkercad.

This is where the tutorials from Tinkercad are useful. Use the zooming and pan/rotate tools via your mouse or trackpad to analyze the model, making sure that all of the detail you need is there. If you see too much missing or some jagged lines, try to find a higher resolution image to start with, and go back to Step 2 and try again.

Adding bits: Tinkercad will also let you add a platform (or anything else) on your model. This can be useful if you have letters in the logo that float free when converted to 3D. Those free-floating insides of “O”s and “A”s will float right off the final product when you 3D print it out, so best to find some way to tack it down. The easiest way to do this is to create a “Geometric” shape from the right sidebar that is an approximate shape of the logo (rectangle, circle, etc.), and give it a dimension of 2mm high. Place it on the platform next to your logo, size it right, make sure it has the same bottom level, then move it right on top of your logo. When both pieces look like they fit, select both at the same time (by simply dragging a select box around the entire thing), and click on “Group” above.

Subtracting bits: If you needed to put a hole somewhere on the model for a keychain, cup holder, etc, all you need to do is follow the above process, but make it a hole instead of a “color”. Use the buttons at the top right to do this. When you “Group” your logo with a small cylinder that spans the height of the model, voilà! It’s a pendant!

Step 8: Export as an .stl file.

This step couldn’t be easier with Tinkercad. Click on the “Design” menu, then “Download for 3D Printing”. Select “.STL”, and the file will start downloading immediately.

Step 9: Find yourself a 3D printer.

They’re popping up everywhere these days: your local library, makerspace, Earth-orbiting laboratory… wherever you are, you’re probably not too far away from a 3D printer with some spare time on its nozzle. If you can’t find one nearby, you can of course order a 3D printer of your very own (we recommend this one, especially if you go the coffee table route) or have someone else print it via a service such as Hubs or Shapeways.

Step 10: Don’t stop customizing!

The skills you’ll learn and feeling you’ll get by going end-to-end in making something that never existed before is like no other. Welcome to the world of mass customization, where you don’t have to make 10,000 of something in order for the act of designing it to pay off. Make some new models.. iterate, experiment, and most importantly, share it! If you make something awesome consider posting it on a model sharing platform such as SketchFab and sharing the link here in the Facebook or G+ comments.

Chris Gerty

Blog Post Author