RepRap replicates 100%

This story in Computerworld is a couple weeks old, and I should be working harder to keep up. Vik Olliver, a RepRap hacker in New Zealand (and probably the hardest-working RepRap hacker in the world), has now fabricated all the parts of the RepRap except the Z flag, which can be cut out of the side of a beer can. This includes only the parts that it makes sense to print on a RepRap, so it doesn't include stepper motors, nuts and bolts, pieces of metal and wood (e.g. threaded rods). But it's an important step.

I myself am still drooling a bit over some of the hobbyist CNC stuff. There's a guy in New Mexico who sells these things on eBay. He sells aluminum ones (like this) and ones made of MDF, which I believe is a sort of particle board. Many low-end CNC machines are in the $2000 to $5000 ballpark, whereas he sells these in the $300 to $600 ballpark. It should be pretty easy to swap out that orange router and swap in an extruder.

I was thinking a bit last night about how to drive those steppers, since the offerings on eBay don't include the drive electronics. Digikey sells a stepper motor sequencer chip, the L297, which would be used to drive some power MOSFETs. The L297 just needs an input to choose clockwise or counter-clockwise, and a clock pulse to advance a step in that direction, so you need six GPIO lines to control the three motors, and one more to turn on/off the router or squirt goop out of the extruder. There's some very good information on stepper motors and driver circuits here.

It occurs to me that I've never posted the Sourceforge download page for the RepRap design files. A shocking oversight, given that I want to see the project succeed and proliferate.

Adrian Bowyer interview, Computerworld

Here is the start of the four-page interview. Much of this is stuff that's been published before. Two parts I found interesting appeared on the third page.

Are there plans to modify the current design to replace non-reproducible parts such as bolts with parts that can be manufactured on the machine itself, bringing the overall RepRap design closer to 100 per cent self-reproduction?

Yes - that is definitely one of the evolutionary paths to greater reproductive success. For the immediate future I will be concentrating on widening the list of materials that RepRap can build with (starting with electrical conductors). That widening will implicitly raise the proportion of parts that it can make for itself, of course.

The Fab@Home people have already done a few embedded circuits by printing with conductive silicone. Making circuitry will be a very important ability for these machines.

Can the RepRap recycle what it manufactures?

Yes, recycling has been built in from the start... The main plastic we are using is polylactic acid...

But I want to move to using a non-biodegradable resin. This too is sourced from biomass, but is stable in the ground. That means that the more reprapped goods that get made from it and thrown in landfill, the more carbon is taken out of the atmosphere and locked away for good. And, in 200 years when we have taken so much carbon out of the air to make stuff that anthropogenic global cooling is starting to be a problem, the landfill sites become our strip coal mines to save us.

This is the first time I've ever heard anybody advocate for putting stuff INTO landfills as an environmental measure. An interesting approach to carbon sequestration.

Coming soon: a complete RepRap kit

BitsFromBytes.com is an on-line store based in the UK which will be offering a complete set of parts for the RepRap for UK£299, or somewhere around US$600 given current exchange rates. They will offer both hardware and software.

I wish I could claim to be so ambitious that I would take a more active approach than simply ordering all the parts in a kit. But I'm as lazy and tired as the next guy, so a kit is really the only practical way I'm likely to do this. And the price is just about right. Months ago, Adrian Bowyer was talking about $400 as a target price for the long term, after lots of self-replicating machines had brought the price of parts down to a minimum. To get so close to the long-term price so quickly is fantastic.

With this kind of head start, the scenario where RepRaps bootstrap themselves to microeconomic ubiquity looks very plausible.

More service bureaus

In a couple of recent postings I have talked about the Ponoko laser-cutting service. Another very interesting online service bureau is Emachineshop.com which is a machine shop to which you send design files created with their downloadable CAD software. They have some examples of the things people have made. Just poking around their website really makes me drool a little bit. I can't believe I'm not doing something with this.

Big Blue Saw is a service bureau that does waterjet cutting of metal and plastic. They cut very thick pieces of metal, which surprises me, I didn't know you could do that.

A couple more: Fabjectory.com specializes primarily in making physical copies of avatars from games like SecondLife. FluidForms makes pretty flowing shapes for things like vases and pitchers. I haven't read about these yet, and as of this writing I don't know what technology they use, or what design software.

Broadening the definition of "fabber"

I want to broaden the scope of this blog a bit. The word "fabber" is generally accepted as synonymous with "3D printer" but a 3D printer has a lot in common with both CNC machines (routers for wood or milling machines for metal) and laser cutters. There are hobbyists building all of these. All of them make a 2D or 3D shape under computer control with relatively little human intervention, and minimal need for human skill.

How many of these gadgets could be self-replicative in the RepRap sense? For example, could one use a laser cutter (or a laser-cutting service like Ponoko) to cut out pieces and use those pieces to build another laser cutter, thereby driving down the cost of laser cutters? As with RepRap there will inevitably be complicated pieces that can't be made that way. CO₂ lasers are dangerous and expensive, so I don't think this could make the kind of impact in the developing world that RepRap hopes to make. A replicating CNC machine might be a better bet, as Dremel tools are much cheaper and safer than lasers.

That self-replicative idea does fascinate me a good deal. It will, over time, drive down the price of the self-replicating thing. That doesn't mean we'll enter a microeconomic paradise, but it promises at least to be interesting and possibly to raise the quality of life noticeably.

I've haven't blogged too much about commercial machines. I want to do more of that. I admire the hobbyists and their perseverance in the face of difficulties, but the technology appearing in commercial machines will gradually trickle down into the hobbyist arena as patents expire.

RepRap parts available via Ponoko

Ponoko is a very cool on-line laser cutter fabrication service with a wide range of available materials. The idea is that you create a EPS file for the laser cutter to follow, specify the material, and they cut out the pieces and ship them to you. The laser can also engrave lines on the material. EPS files can be generated with Adobe Illustrator or various other similar 2D artwork programs. If you want to make a 3D project (like this table), you make it out of 2D pieces that fit together with slots and grooves. When you upload your EPS file and choice of materials, they figure out how much the laser cutting fee will cost.

Toby Borland (of SMARTlab in the U.K.) has designed a set of laser-cut plywood RepRap parts and made the EPS files available on the Ponoko website. There is a Flickr photo set showing laser-cut RepRap parts and the process of assembling them; I am not sure that's the same Ponoko files and process, or another laser-cutting effort, but it gives you a sense of what's involved, and the level of complexity.

Those commercial 3D printers sure are gittin' purty

Some commercial 3D printers are very pretty. This one prints in colored plastic and is intended to create prototypes in a few hours that can be shown to managers or customers. The claimed resolution of this thing (presumably in all three dimensions) is 450 dots per inch. Drool.

In twenty years, all the patents for this printer will have expired, and it will be possible for hobbyists to make such pretty stuff at such high resolution. Hmm, thinking more about that inclines me to start an economics blog, since I blog about economics a lot elsewhere.