How to Build Anything Out of Aluminum Extrusion and 3D Printed Brackets

The real power of 3D printing is in infinite customization of parts. This becomes especially powerful when you combine 3D printing with existing materials. I have been developing a few simple tricks to make generic fasteners and printed connectors a perfect match for aluminum extrusion, via a novel twist or two on top of techniques you may already know.

Work long enough with 3D printers, and our ideas inevitably grow beyond our print volume. Depending on the nature of the project, it may be possible to divide into pieces then glue them together. But usually a larger project also places …read more

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Laser Surgery: Expanding the Bed of a Cheap Chinese Laser Cutter

Don’t you just hate it when you spend less than $400 on a 40-watt laser cutter and it turns out to have a work area the size of a sheet of copy paper? [Kostas Filosofou] sure did, but rather than stick with that limited work envelope, he modified his cheap K40 laser cutter so it has almost five times the original space.

The K40 doesn’t make any pretenses — it’s a cheap laser cutter and engraver from China. But with new units going for $344 on eBay now, it’s almost a no-brainer. Even with its limitations, you’re still getting a …read more

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A How-To in Homebrew Design, Fab, and Assembly with Structural Framing Systems

At this point, the internet is crawling with butt-kicking homebrew 3D printers made with extruded profiles, but it’s easy to underestimate the difficulty in getting there. Sure, most vendors sell a suite of interlocking connectors, but how well do these structural framing systems actually fare when put to the task of handling a build with sub-millimeter tolerances?

I’ve been playing around with these parts for about two years. What I’ve found is that, yes, precise and accurate results are possible. Nevertheless, those results came to me after I failed and–dry, rinse, repeat–failed again! Only after I understood the limits of …read more

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