Creality CR-10 Mini “Cold Pull” and Bowden Fitting Cleanout

April 4th, 2021 by Keith Neufeld

Had a bit of a filament jam on the Creality this week, and today I tried a “cold pull” procedure with the intent of cleaning any foreign material and scorched filament out of the nozzle. I think that was an issue needing to be solved, but I also created another problem along the way.

3D printer filament blobs from nozzle cleanout

In the background, you can see that I’m not as good at cutting glass as I am at … well, let’s not make any hasty characterizations I’d regret later.

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Blue 3D-Printing Build Surfaces Are Great

January 7th, 2021 by Keith Neufeld

Creality CR-10 Mini 3D printer with print

I am loving this slightly-textured build surface. ABS sticks to it well enough not to peel even without an enclosure, and PLA works great, too. The texture is just enough to make the bottom of a print blend in with the other faces. So far it’s providing so much better results than my Prusa PEI spring steel sheet that I’m on the verge of ordering a clone spring steel sheet and covering it with this.

You can find them on Amazon by searching for “blue 3D printing build surface” (or just “3D printing build surface”) and scrolling through the inevitable irrelevant Amazon results until you find the offerings from Chinese companies named <random letter> <random letter> <random English word>.

And, er, I bought a secondhand Creality CR-10 Mini (300 mm x 220 mm build area) to be able to print something a little longer than my Prusa can do.

MakerBot CupCake’s Triumphant Return, Part 2: Skeinforge Slices; CupCake Prints

October 31st, 2020 by Keith Neufeld

With the CupCake printing successfully again, the next step was slicing so that I could print new things instead of only reprinting G-code that I’d saved in 2012.

As noted before, I hadn’t figured out how to get Skeinforge to run on a current computer, after losing my previous Skeinforge installation to the crashes of both my personal desktop and laptop computers, on which I had all of the data and none of the software or configurations backed up. (I’m wiser now.)

I struggled figuring out how to get Skeinforge running again now, in part because I think the instructions that come with it never got updated as its capabilities did. No, I am not going to copy the STL into the system executable directory every time I want to slice something and then move the resulting G-code back out. It turns out that any version of Skeinforge that I might actually want to run has a file browser and remembers where you browsed the last time you used it; so it’s pretty easy to get along with.

And as to which version I actually want to run, one of the files I did have backed up was my detailed notes on fine-tuning Skeinforge settings for my CupCake, which (naturally) included the fact that I was running Skeinforge 0035. So there we go.

3D printer calibration objects

With slicing working, that just leaves calibration, and I’ve done that now too.

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Replacing a Pollcat Power Supply

October 3rd, 2020 by Keith Neufeld

Replacing a power supply should not be a noteworthy task; but when an exact replacement for the failed power supply isn’t available, one wants to exercise some care and diligence installing a compatible-but-different power supply.

Shamefully long ago (cue Wham’s delightful “Last Christmas” and sing along to ignore the guilt), one of the two redundant Pollcat telephony call-detail-monitoring gateways at work didn’t recover after datacenter electrical maintenance. Last weekend I finally looked at it, confirmed that the power supply was dead, and confirmed that the rest of the unit operated fine when run from bench power.

Pollcat shown with new and broken power supplies

I couldn’t find a reasonable source for the original model of power supply (the right of the two, toward the center of the photo); so after a bit of searching came up with different a 5-VDC 2-A open-frame power supply (the left, on some bubble wrap) that can physically fit into the available space in the enclosure and that can also operate from 100-240 VAC (important for datacenter 208 VAC) for a very affordable $10. We ordered a couple of them and I got it replaced this afternoon. I expected from the beginning to have to make a mounting adapter, but I also had to mind the polarity of both the AC and DC power connectors.

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CNC Fabric Cutterhead Prototyping: More Torque (Less Speed)

September 21st, 2020 by Keith Neufeld

The previous cutterhead prototype from about a year ago that used a tattoo gun motor reciprocated the blade at a high speed and cut the fabric well, but stalled easily in the foam spoilboard. I needed more torque and I was hoping I could get by with less speed.

micro gearmotor

And now I remember how I stumbled across the idea to use a tattoo gun motor — Nick Poole’s SparkFun post on building a tattoo gun from one of their cute widdle gearmotors, which are available in a wide range of gear ratios and output speeds. So when the tattoo motor didn’t have enough torque, I ordered two different speeds of the micro gearmotors from SparkFun, following Nick’s path of innovation.

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Prototyping a CNC Fabric Cutterhead

September 20th, 2020 by Keith Neufeld

If I’m going to try to develop a CNC fabric cutter, it’s going to be called the CutterRouter.

There, got that out of the way.

If I’m going to try to develop a CNC fabric cutter, at least the prototype and ideally the final version will use all commodity components plus easily-fabbed parts (3D printing, lasercutting, easy woodworking with common shop tools and not requiring a high degree of accuracy). The self-imposed choice of commodity components makes me want to use a readily-available X-ACTO® blade as the knife.

If I’m going to try to develop a CNC fabric cutter, I want to develop a working prototype cutterhead first. It’s the only part of a CNC fabric cutter that’s significantly different than a 3D printer or mill. So if a cutterhead can be made to work, the rest is easy; if it can’t be made to work, the rest is moot.

prototype reciprocating-blade cutterhead

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CNC Fabric Cutting

September 19th, 2020 by Keith Neufeld

Surely by now the sewn-product industry has CNC fabric cutting?

Yes, but I don’t know much about it and my acquaintances haven’t worked at places that use it. What I’ve been able to find appears to start around $30-40K for a fairly short table, with extensions available. That entry pricing only makes sense for a fairly high volume of product.

Could we do better, and is there a market for it if we could?

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How Fabric Is Cut for Product Development and Made-to-Measure Production

September 18th, 2020 by Keith Neufeld

In the sewn-product industry, product development can have a rapid-iteration phase that would be familiar to anyone in hardware or software development. Whether it’s testing the fit and strength of a new backpack or checking the fit and appearance of a garment on the fit model, a single prototype at a time may be made and revised weekly, daily, or even more often.

In the garment industry, “made to measure” refers to clothing whose pattern is made from measurements of the individual wearer and then either drafted algorithmically or pieced together from library parts for each possible value of each collected measurement.

In product development and in made-to-measure production, a number of factors of fabric cutting are different than in mass production:

  • The manufacturer or producer may be making a single quantity, certainly only a small quantity.
  • The manufacturer or producer is unlikely to be making multiple sizes at the same time.
  • The above factors rule out the long markers used in mass production.
  • The above factors rule out lay-ups of many plies of fabric.
  • The manufacturer or producer may not even have a marker — pattern pieces might be hand-drafted and on separate pieces of paper or oaktag (card stock).

I can’t speak definitely about every possible cutting scenario in product development and made-to-measure production, but I can cover common cases.

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How Fabric Is Cut in Industry

September 17th, 2020 by Keith Neufeld

Eastman Class 134 rotary fabric cutter

I volunteer in the sorting room at my local thrift store about once a week and a few years ago, one of the guys who processes electronics and appliances showed me this thing out on the sales floor and asked whether I knew what it was. Pizza cutter? Linoleum cutter? Don’t know; but it’s a beautiful piece of machinery, so I bought it.

By the time I left the store that night, we’d figured out together that it was a fabric cutter. And as it happens, by now I know a lot more about the topic than I did then.

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Vintage ED-Lab Prototyping Station

September 16th, 2020 by Keith Neufeld

Spotted at a thrift store.

Of course anything with that many knobs and jacks caught my eye, and it’s in fantastic cosmetic condition.

Looking more closely, the function generator would have been a dream to have when first learning about op amps!