3D Printed Connectors

Above: connector with aluminum insert

Challenge: To create larger objects, using the 3D Printer to create connectors to go at the corners to ensure that the large structure could be build.  In this instance the ultimate goal is to produce a hydroponic set up for the students.
Background: The teachers and students were looking at additional design tasks to extend the students.  This project is a significant one, that is being drive by using the 3D printers to create connectors to allow the build to progress with aluminum pipes which has been custom cut for the project.
Task: Some of the old filament from the first 3D Printer (2014) was used along with additional prints.   The size and dimension of the aluminum piping determined the width and the size of the connection.  As the design was based around a large rectangle shape the connectors needed to have three links on each of them.

Level of Difficulty: Low - the connectors dimensions were determined by the aluminum piping and its dimensions so it was obvious what was required.  Various tests on the width and the fit of the connectors were made to ensure that there was a close fit, although its anticipated that the final version will require some form of permanent bonding.
Issues: None - although the ultimate success of the project will depend on the additional pieces this is the first time that custom made connectors for a project have been 3D printed.
Size: 4cm x 6cm x 4cm.  Dictated by the role of the connectors and the size of the aluminum piping used.
Timeframe: Multiple connectors were printed on the bed at each time to ensure as many as possible were produced, resulting in an overnight print (which would mean individual pieces would be produced in a four hour print).
Process: The students used Tinkercad to produce the files which were converted for the printing.  The older filament, which is dating back to the end of 2014 was able to produce a workable print.  Tinkercad/Cura were utilized again, as was the Ultimaker 2+ which was able to produce better quality prints than the others produced by the Ultimaker 2.  There are considerable prints to follow in this series and they will be updated in posts to come on this site, including assembled pictures of the piping.

Raspberry Pi 3 - Printed Case: 3D Printed Cover

This is an alternative version of the cover for the previous project.  In the example the teacher had used a School Milling Machine to create a plywood cover the for the Raspberry Pi 3 Box.   On discussion with the teacher about the project he indicated that he had initially produced a 3D printed lid, and decided to go for a wood finish for aesthetic reasons.  This photograph is of the other option for a lid, and features the Raspberry Pi Logo.  It was screen shot and then imported directly into Tinkercad.

The shot to the left shows the base of the cover, which included a stand built into the design.  It was a 12 hour print without rafting on a regular setting.  (Please note that all prints from now on are primarily being carried out on an Ultimaker 2 which has an expansion kit installed on it, the Ultimaker 2+)

Raspberry Pi 3 - 3D Printed Case

Challenge: The teacher concerned had a Raspberry Pi 3 and wanted to produce a case to keep in secure and protect it.  To do so used a combination of machines and Tinkercad.  He used a milling machine to produce the wooden lid and then used the Ultimaker 2 to 3D Print the case.
Background: This project was originated by the classroom teacher as an individual project.
Task: Produce a workable case for a Raspberry Pi3 which would protect the device but also also for the device for being fully operational.
Task: The dimensions for the project were sourced from plans available on Thingiverse, although the teacher did not use these plans, he still created an original piece in Tinkercad.
Level of Difficulty: Moderate - although this was a teacher designed and originated project students could replicate it by following the process.    The original measurements were taken from a third party and this was possibly the most challenging part of the process.

Issues: None - the teacher purchased a set of nylon nuts to complete the process and ensure that the lid was secured to the base.  The 3D Print was completed with the Ultimaker 2 (which is an upgrade kit in addition to a regular Ultimaker Printer.
Size: 9.5cm x 3c, x 6.5cm.  (which is the dimensions of a device to house the Raspberry Pi 3).
Timeframe: 3D Printed components: the base was printed in an overnight print on regular Ultimaker2 3D Print settings.  The timeframe was approximately twelve hours.  The lid was produced by a school milling machine and took two days to cut the wood.   The wood was then lacquered with spray from a spray can, and left to set.    The Plywood lid was a regulation piece of wood.
Process: This was a little different in that Thingiverse was the first port of call - however this was to gain the measurement specifications to make the base.  Both the base and the lid were designed in Tinkercad and milled and then 3D Printed.   They were then joined by the screws.    The design of the Raspberry Pi Logo was screen shot and then dropped directly into Tinkercad.

Door Signs/Classroom Passes

Note: Attempt at having a join created by printing

Challenge: This project was teacher initiated.   The teacher was looking for a way to use the 3D Printer to create a sign for placement above the door of the classroom - as the finished product was approximately 30cm this was also the perfect size for a classroom pass.  Previously I have worked in schools where students had to have one of these when leaving the classroom to go to other locations.
Background: As detailed above.  The teacher was looking at a dovetail approach to join together two separate prints (see below) we are very fortunate with the Ultimaker 2 that we have a large base to print off.  The length of the combined print was thirty centimetres.

Whare Paku translates to 'Bathroom'

Task: The idea was to link two separate 3D prints together to form a solid print.
Level of Difficulty: Using Tinkercad the task was straightforward and followed the format of the previous prints.  The details were then pulled out of the base sign.    Overall: Low (however it is important to read the note below about the joining of the print).

The wood version of the sign milled from wood

Issues: The join failed.   The teacher had attempted to create a 'dovetail' join for the two separate prints.  The two interlocked however the teacher had to force the two together by standing on them, in doing so this produced the crack that is visible.   The print had been completed on a draft setting which possibly contributed to the failure of the join.   The idea being if they interlocked and were strong enough any bonding (such as glue) would not be necessary.
Size: 30cm long by 5cm high and depth of 4cm.  
Timeframe: Each of the two sections was twenty hours on fast print setting.
Process: Tinkercad for design converted to Cura 2, then downloaded on a memory card and direct print.  Following the failure of the join the teacher concerned used the School milling machine to wood cut the same design into a sign.  He used his original Tinkercad 3D Print and then altered the lettering to produce the print.

Student Creation: Money Holders

Above: Student design shown to scale

Challenge: Previously students had designed boxes to hold classroom cash as designs from the student.  These boxes had times ranging from 35 to forty hours for the base.  As an alternative the student concerned designed a holder that was a single figure.  This is the same student who had previously designed and created the 'pencil topper' print and design.

Background: The task was to create a holder for the students 'classroom cash' that are rewarded to students for excellent behaviour.  Previous designs were based around a full sized box.

Task: Students to create a workable print that was original and creative.

Original Design in Tinkercad with insert clearly visible

Level of Difficulty: Medium on the basis that the design was up to the students and the detail was dependant on the design.  This is shown further refinement from the 'pencil topper' design.

Issues: None.   The student was able to produce a limited amount of rafting with the project and the print was completed in a single print run.
Size: Length of 6cm (high), width (5cm)
Timeframe: Six Hours on Fast print setting.

Above: front on final print

Process: The student (who is ten years old) has shown the creativity to create original designs from scratch using Tinkercad and a laptop as creative tool.  He is confident and enjoying the process.  He is developing his ideas around geometric shapes and applying the problem solving.  Design from scratch using Tinkercad, converted to Cura for 3D printing and printed on an Ultimaker 2.
Recommendation: The student has been pleased with the quality of the print and the design of the animal.  There is a clear evidence of his progress using Tinkercad to create animals/shapes and the student is becoming recognised by his peers as a problem solver.  The print time would mean that the print is realistic as a holder for a variety of objects and could be easily modified to hold other objects depending on the needs of the students.

3D Prints: Student Improvements and Refinements

Above: Token Box version 2.0

Above: Token Box with tokens.

When the students start utilizing the technology they are showing consistently that they can improve designs that follow later in a sequence.

Already we've recently documented on this site projects such 3D Printed Student Token Box, since this print another two designs in the sequence have followed - the latest of which is shown on the right.

Above: 'Fish' Designed Cookie Cutter

The shape has changed considerably from a box like shape to a circular dish, also the lettering which was sunken in with the initial design has now evolved into having it standing out from the print.     The size and most other details contained with the original post are all still relevant and therefore we will not be posting this in its entirety.

There are a number of 'Cookie Cutters' currently in production.   The first of these was the 'Golf' themed Cookie Cutter detailed in a previous post.   Following this initial production a group of students have produced different themed versions of this creation, which have allowed the students to be creative and also produce something unique.  There will be a separate post on this material, featuring a range of student designs shortly.

Finally as previously described the students who are competing in the Junior Robocup Competition involving Lego NXT/EVO3 Robots have been utilizing the 3D Printers to create props for the performance.   Following the initial creation of a few props students have started to realise the potential of the machines and how to integrate them successfully.   The latest prop to appear is the sign featured to the right.  The sign design initially was created by having the students write onto cardboard and then have it sellotaped up.  Upon seeing some of the props that were being produced the students created this sign for the performance.   It was created by a Y5/6 student, using Tinkercad and the regular production process.  The sign is 15cm long, 12cm high and was produced on 'fast' setting over a five hour print.  The sign is requiring to be re-printed as the lettering was produced individually on a ledge, without rafting.   The lettering was put together individually and dragged out of Tinkercad and as a result isn't uniform in size.

Student Creation: Pencil Topper

The Print before it was removed

Challenge: Student brief was use the 3D Printer to create and design something that was of practical use in the classroom.
Background: The classroom mentioned has been where a lot of the recent featured work on this site is coming from.  The students are showing increased aptitude with the 3D Printers and are feeding off each other to produce creative and interesting designs.   This task started as a isometric design in Tinkercad with an oval for the base, the features of the chicken came as a consequence of applying shapes.  The final stage was to determine while the print was finalised what the purpose would be.  It was decided the most practical use was as a 'pencil topper' an object to sit on a regular student pencil.

Note egg shell on the head of the chicken

Task: Students to create a project for the 3D printer that was original and innovative.
Level of Difficulty: Low - the design was original and a free task.
Issues: The eggshell design on the top of the design didn't print as anticipated, however there was no attempt at any rafting.
Size: 10cm by 15cm
Timeframe: Four hours on a fast print setting.
Process: This print came as an organic creation process involving a design with Tinkercad - as mentioned the brief  was a creative design that originated from the students, to use the printers.
Recommendation: This process should hopefully lead to another group of students to utilize the printers and to do so in a more creative manner.  This is a basic introduction task as a stepping stone for more complex tasks.  By having it in the classroom in a visible place it would work as a conversation starter too.