Hackaday Podcast · 4 Oct 2019 · 52m
Hackaday editors Tom Nardi and Mike Szczys review weekly hacks, including a discussion on the trade-offs between resin and FDM 3D printing, a silicone injection molding machine, and a mechanical keyboard wiring project. They also cover a Raspberry Pi-based Sidekick clone, a 3D-printed thermal insert press, and a hydrogen-line telescope. The episode highlights the complexity of moving from FDM to resin processes, emphasizing the need for batch printing and post-processing care. Additionally, they discuss off-world cement testing on the ISS and a DIY wire-bending robot.
makers and hobbyists
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Jimmy Diresta, Bob Clagett, and David Picciuto discuss their experiences with 3D printing and CNC machining. They cover specific technical challenges, including extruder failures on a Delta Go printer, bed adhesion issues, and the design of a trike from found materials. The conversation explores the practical applications of 3D printing, such as making cookie cutters and camera accessories, while debating its role in modern manufacturing versus traditional methods.
Jimmy Diresta, Bob Clagett, and David Picciuto discuss their current 3D printing projects, with Jimmy using a Bambu Lab X1 Carbon and Prusa XL for practical shop organization, and Bob exploring castable resin for bronze bell casting. David Picciuto shares his experience with an Elegoo Saturn 3 ultra and water-washable resin, while the group debates the value of creating art for art's sake versus functional objects. They also address the creative challenges of YouTube content creation, brainstorming hooks for videos, and the importance of scheduling dedicated creative time to overcome mental blocks.
Greg Paulsen, Director of Applications, Engineering and Marketing at Xometry, discusses the complexities of rapid prototyping and the transition to mass production. He details the pros and cons of various 3D printing technologies, including filament-based FDM, powder bed fusion (SLS, MJF), and resin-based methods (SLA, DLS), explaining how each affects design constraints and scalability. Paulsen highlights common hardware horror stories, such as designing for 3D printing without considering injection molding requirements, leading to prohibitive costs and tooling issues. He emphasizes the importance of clear communication with manufacturers and using AI-driven tools to optimize designs for manufacturability early in the process.
Steve Szymeczek of Penumbra Engineering explains the practical applications of additive manufacturing for low-to-medium volume production, contrasting it with traditional injection molding. He details the cost-effectiveness of technologies like FDM and HP Multi-Jet Fusion for startups needing 100 to 10,000 units, emphasizing the importance of designing for injection molding even when using 3D printing for prototyping. Szymeczek also discusses the benefits of distributed manufacturing, material limitations, and the role of generative design in creating complex, value-added parts.
Andre Tiemann, Director of Production at Hot Pop Factory, explains how 3D printing serves as a critical tool for hardware startups across three stages: rough ideation, engineering prototyping, and short-run manufacturing. He details the evolution of materials from early ABS to modern engineering-grade plastics like Nylon and Rigid 10K, and contrasts processes like FDM, SLA, and SLS. Tiemann emphasizes that using additive manufacturing for low-volume production (50-500 units) de-risks product launches by allowing market validation and customer feedback before committing to expensive injection molding tooling.
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