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Showing posts with the label 3D Printing

Infinity Mirror Dodecahedron

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This was a fun project I made after building the infinity table and being happy with the results. In this project, I learned how to design a PCB and got a little bit more experience with electronics, Arduino programming, and Fusion 360. By putting 12 reflective acrylic pentagons in a dodecahedron shape sticking 420 LEDs inside I made the infinity effect shown in the pictures. 

1 Horsepower 80,000 Lumen LED Flashlight

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This project started a while ago when I found out 100w LEDs are as cheap as $2 each on eBay . I finally finished the project up this summer when I got sent back home from college due to coronavirus. The flashlight consists of 8 100w LEDs and reused batteries from the electric hydrofoil project . 

Bloom - Kinetic Art Zoetrope

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In this project I tried to make a " bloom " similar to the ones created by John Edmark. I used Matlab to generate the files which I post process in Fusion 360. This project was somewhat successful, I was able to get the zeotrope effect in some areas of my model but other parts looked like a flickering blur. 

Designing a FSAE Battery Pack

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I was the electric powertrain lead on RIT's FSAE team this year and part of my job was designing the battery pack for our electric race car. The hardest part of this design was the tradeoffs between different cells, mechanical constraints, and electrical constraints. Luckily myself and the other people on the electric powertrain team learned a lot from our previous batter back designs and we were able to make some major improvements to this design.

Metal Additive 3d Printed Lighthouse

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I was lucky to be given an opportunity to print a trinket on a PBF 3d printer. After some brainstorming, I settled on a spiral staircase lighthouse surrounded by waves inside a decorative egg shape that balances on its end like a roly-poly toy. The modeling for this part took a long time and I'm pretty proud of it; I estimate it took ~30 hours total between brainstorming, sketching ideas, writing scripts, fighting Fusion 360, and file prepping for the 3d printer. 

3d Printer Steak, Dishwasher Salmon, and other cursed engineering student foods

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Sues vide is a method of slow cooking that involved putting meat in vacuum sealed bags in precisely temperature controlled water to ensure a perfect internal temperature. Fortunately, a 3d printer heated bed offers very accurate temperature control and zip lock bags can work in a pinch.

FSAE Integrated High Voltage Distribution Board and Enclosure

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In this project, I designed and integrated a PCB for our FSAE car which safely discharges the high voltage capacitors in our inverter from 360V to <60V, controls the TSAL (large high voltage indicator light), and creates safe high voltage measuring points. This project was a really great experience because I got to learn Altium and get a much understanding of circuit board design.

Julia Vase - 3D Prints Generated Using Fractals

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A while ago I took a fractals and chaos course. One of the fractals we learned about was the Mandelbrot Set and its respective Julia Sets. The Julia Sets have some interesting properties which make them very easy to 3D print. I made a MATLAB program that generates Julia Set fractals and exports a 3D printable stl file based equations describing a path through the Mandelbrot Set.

3D Printing a Formula SAE Dashboard

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In this project I designed and 3D printed the cover for our dashboard on my FSAE team's electric racecar. I tested press-fitting different colored 3D prints into each other to make our logo and was pretty happy with the results. 

Experimenting with 3D Printing Wood PLA

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I recently purchased some Wood PLA and made a few small projects with it. Wood PLA is like regular PLA 3D printer filament, except around 30% of it is made of wood particles. This results in a slightly weaker plastic that looks and smells somewhat like wood. I modeled new versions of the trains from the popular board game colt express , 3D printed them to replace the cardboard trains that came with the game and painted the wood PLA with gel stain to make it look more like real wood.

Designing a 3d Printed Hub Motor Cooling Jacket (FSAE)

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This was an R&D project I worked on to further my FSAE team's development toward building an AWD electric racecar. The goal is to cool a 20kw electric motor as efficiently as possible in a robust and lightweight design. This project was really interesting because I got to use CFD for the first time. I learned a lot about fluid flow and thermal design, and the nuances of using CFD.

Lots and Lots of 3D Printed Puzzles

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One of my hobbies is making puzzles which aligns perfectly with one of my other hobbies, 3D printing. I recently messed around with Burrtools , a software used to generate specific types of puzzles known as burr puzzles. Some of these puzzles take dozens or even hundreds of moves to complete. In this post I go into detail on a few of the unique puzzles I designed.

Arduino Controlled Chime Machine (RIT - MECE 104)

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This was a project I worked in MECE 104 - Engineering Design Tools. In this project groups of 4 built chime machines with at least 6 notes to play a song of their choice. I was the programmer for my group and got a good introduction to Arduino programming and motor control. Final chime machine We chose to play  Take Me Home, Country Roads by John Denver because it only required 6 notes and the beat wasn't super fast. At the end of the project, all 32 groups voted on the best chime machines. Our machine was one of the 6 selected to play at the Imagine RIT event in the fall. 

3D Printing an Electric Hydrofoil Surfboard for an English Project

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The electric hydrofoil surfboard is by far my biggest 3D printing project. I got the idea off a forum  I found and decided to make an electric hydrofoil surfboard for WISE. WISE is an English class for seniors at my high school where you have a regular English class for the first half of the year, and a large personal project for the second half of the year. One of the engineers from my robotics team agreed to be my mentor for the project.

Designing a 3D Printed Board Game

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This was a project I worked on with a robotics mentor who's into board games. I designed and 3D printed the pieces but never got around to fully playtesting the game and finalizing the rulebook. I learned the basics of gear design and improved my 3D printing skills during this project. In total, I used almost 2 rolls of PLA filament to print all the pieces.