Modifications
I am by nature never completely satisfied with my machines; I therefore am inclined to tinker and modify everything, even if it already works. Pictured below is a sampling of some of my more successful modifications, most of which I feel should have come from the factory. It is worth noting that these were not my design but were licensed under Creative Commons, meaning that reproduction is unlimited for non-commercial purposes. My penchant for printer-wrangling eventually lead me to help one of my teachers fix his printers on more than one occasion.
It is also worth noting that black PLA from Hatchbox has been my go-to filament for years. The below prints represent many, many rolls.
Belt Tensioner
E3D V6 and FANG Shroud
Modified FANG for smaller fan
Default Replacement Shroud
The Belt Tensioner served to resolve the natural stretch of fiberglass-reinforced rubber belts. The E3D V6 replacement and the corresponding shroud eliminated many of the reliability problems with the factory-installed bowden extruder and cooler. The modified FANG provided newly adequate part cooling for PLA and PETG prints. The default replacement shroud allowed the provided fan to serve to purposes: part cooling and extruder temperature control.
For a perfectionist, 3D printing can feel like sheer torture. Above left is a sampling of poor layering, and above right is a sampling of good layering. A keen observer immediately senses problems with prints, but to diagnose those problems is a much greater challenge. So many things can go wrong with printers: loose belts, temperature fluctuations, bad settings, badly set screws, an unfastened print bed, unreliable filament, a clogged extruder, overly-thin walls, bad designs, or humidity, to name a few. If any one thing is off, the whole print looks bad. Only when everything is right does the maker emerge victorious.
Projects
This was the first draft of my needle cutter, whose purpose is described in the MPCNC page.
This was the second draft, which featured small bearings to align the needle.
This project was a collaborative one. Jason Hitesma and others were crucial with their CAD contributions to the design, and I like to think that I was helpful with my execution and testing. It was also informative: the materials challenges of work hardening in the needle and overheating the welding tip (which seemed impossible) combined to send one of my needles flying, embedding itself in my shop's ceiling, making me glad that I wore eye protection.
The tearout visible to the left was the chief challenge I faced once I got the cutter working semi-reliably. It turned out that my sharpening technique of spinning the wire on the bench grinder created an asymmetry of roughness, making the needle drag when pulled in a certain direction.
Electric Violin
Having been a lover of classical music for as long as I can remember and a violist for several years, I was immediately enthused when I encountered this design on Thingiverse.
The actual printing and assembly were fairly simple, but the cheap pickup I used meant that the instrument sounded unacceptably bad.
I therefore used the project as an attempt to learn about filler primer and painting. As you can see in the image to the right, the automotive primer I bought at the hardware store was effective in filling in the layer lines. My spray painting skills still require work (as do my camera focusing skills) , but I was pleased by the information I gained through this experience.
Prints
These are all parts that I designed as part of an ongoing project: a 3D printed desktop lathe. As far as I know, the second image from the left represents something unique: a 3D printed fully locking ball-head joint that I will use for the tool rest.
Self-watering planter
Pencil and Pen Holder
Impossible Dovetail: A Carpenter's Exercise
I've designed and printed more, but these are some of my "greatest hits." If you are looking for more work, I would be happy to provide it.