However, after bonking my head in the basement I also found the latest Jameco catalog, and something about it just isn’t right.

I discovered this while getting ready to assemble my Mk.7 Stepstruder and realized I could print another pair out faster than I could dig through the entire house looking for the first set I printed.

Which makes me wonder — why can’t I do this when I can’t find the cap for my pen or some random generic plastic part for a battery pack? If it’s easier to print one out than find it, what happens when I find the one that I lost? Toss the one I printed in the Imaginary ABS Recycling Bin?

Is the answer different? In my limited experience, yes. You can make a lot of useful things with a laser cutter, but it’s not as trivial to own as a 3d printer. To begin with, the laser cutter is far more dangerous to operate than a 3D printer. Most of us think of cheap red laser pointers when we think “laser”, but those a far cry from a Class IV “cutting” laser that can sever a finger or permanently blind you.

Oh, and it’s invisible. An invisible laser that can permanently maim or kill you. Thus the various safety interlocks that prevent the machine from operating when the door is open, just like a microwave oven.

That being said, I think laser cutters are in the same class as “professional” 3d printers used in manufacturing. It’s probably not something you would own as much as something the local co-op or library or commercial printing shop would own, maintain, and use for you. When you need a stack of flyers printed and go to the local print shop, they run the machine for you, it’s not going to be much different than that.

The other issue is finding a place to use it safely. Laser cutters are safe to operate in self-test/alignment mode, but as soon as you start cutting and etching you run into the problem of toxic fumes.

Most of the media I’ve seen go through a laser cutter has been acrylic, polycarb, and other plastics — all of which generate some seriously nasty fumes when they are etched or cut. My experience is that the warnings in the Plexiglass(r) MSDS are %100 correct. Not only do you need space for a laser cutter, you need an exhaust fan that can move a lot of air outside very quickly. (The commercial Epilogs I’ve used had fans that were loud enough to drown out normal conversation, I don’t know who specified them so they might have been overkill.) Cutting / etching wood has similar problems — lots of smoke from the wood and whatever byproducts come from burning the glue if you’re cutting plywood. Paper’s not really a problem, and cutting PVC and some other materials will actually destroy the lens so those aren’t cut in the first place.  [Edit: When laser cut, PVC releases free chlorine gas which combines with atmospheric oxygen to form hydrochloric acid which is bad for the mechanicals.  I suppose If you had a laser cutter filled with an inert gas it only be a matter of safely disposing of the exhaust gases.]

So going back to the original question, I think the answer for now is “because they can”. If you have the space (a big garage or a studio/hackerspace) and time (I’ve got 50+ hours into my lasersaur build) it’s certainly an experiment worth trying.

Currently there’s just an antenna mount of interest only amateur radio people, but I’m working on a few more items on the store that I am prototyping with my Makerbot Cupcake before uploading to Shapeways.

Recently I picked up a Barnes and Noble NOOKColor. It’s an Android-based, e-reader/tablet with a good web browser and PDF display package. I don’t plan on buying many e-books (I prefer paper), but having something bigger than a phone and smaller than a laptop that can display a PDF or browse a “howto” site while I’m in the studio is seriously useful.

Except for one slight problem.

Like most tablets/e-readers, it’s meant to be hand-held and not parked on a bench. If I lay it flat on my bench it’s hard to read, and while it was amusing to have my hand model hold it, that didn’t work well either.

So after a frustrating day of trying to use it to browse instructions on some MakerBot mods…

[facepalm]

… a trivial NOOKColor holder.

I had an idea recently for a different way of making ground plane antennas for the 2M band. Don’t worry about what they actually are, suffice it to say that they occupy a lot of volume and are a pain to transport. Imagine a pyramid made out of four 60cm coathangers with another 60cm coathanger coming out the top of the pyramid and you’ve got a typical ground plane antenna. On the other hand, they’re cheap, easy to build and can be tuned/adjusted with the SWR meter in a decent VHF radio.

(Ok, that’s pretty much all the geek stuff out of the way. See, that wasn’t so bad, was it?)

So here’s the problem. What if you want to toss a ground plane antenna in the back of your car, carry it somewhere on your bicycle, or have it as part of an emergency “go bag”? Are you really going to cart around a delicate bit of metal sculpture that occupies a rectangle a half-meter on each side and a meter tall? No, you aren’t.

This became a problem with an interesting combination of design and fabrication: How I could make it easier to transport and store but still be easy to set up and function correctly as an antenna? The idea of making it fold up seemed like the most obvious solution, but folding means moving parts which means more chance of coming apart. However, most people use this sort of antenna in a fixed location, often inside an attic or outside resting on a flat surface. At worst it might be used outside in windy situation and I’m thinking about a second version for that sort of environment. I started my process with the traditional sketching but instead of making foamcore models I decided to fire up the MakerBot Cupcake I built last winter and start out with ABS prototypes.

Total time spent modeling and printing each iteration was about an hour, and it was easy to fit that in at night after dinner over a few nights. The first few didn’t work very well but I quickly hit one that did work and that was a relatively simple piece of plastic. (Ok, it worked better after a bit of filing and sanding, but it worked.) Within a few minutes I’d bent and cut some welding rod, soldered a stick of it to an adapter, tweaked the resonance a bit, and I had a working antenna for not very much money.

The problem quickly became “How do I share this with other amateur radio operators?” Sure, I posted the STL on Thingiverse, but you have to own or know someone with a 3D printer for that to be of any use.

I think the answer is going to be Shapeways. I’ve ordered printed items from them in the past and while they aren’t cheap, they have wonderful print quality and ship worldwide. I’ve started the process of setting up a store there and in the spirit of Amateur Radio will offer my antenna mount for minimal markup.

In a few months we’ll see how this experiment worked: Can a design concept prototyped on a hobby 3D printer be turned around and sold for a small profit by a commercial fabrication shop? What are the unexpected surprises or hidden gotchas that need to be solved for this to be more than a hobby and instead a viable business model?

The DSLR is a great tool for documenting 2d and 3d design, but for 4d design you really need something that can capture video. (It’s true that some DSLRs now capture stunning video, but only for short durations and quantities and you’re still lugging around a full-size camera.) My “should have brought the video camera” regret kicked in as soon as I started experiencing how differently Japanese people interact with technology and their environment. Sure, I could take lots of photos and copious notes, but those aren’t nearly as good as 10-15 seconds of video.

It’s not just recording video that’s important, it’s being able to record video conveniently, in high quality, then easily move the video off the camera. With my full-size, miniDV video camera it’s pretty much impossible to take quick snippets of video given the overhead of getting it in/out of the case, turning it on, etc. On the other hand, the TGV5 is small and light enough that I can carry it in my pocket and within a few seconds have it out and recording video. (It’s even faster than getting my Droid out and recording.) Cheap/free software makes it trivial to take a 10-20 second clip, trim it if needed, then “Save As” for Flickr or Vimeo.

As an experiment I’m starting to document design — especially 4d design — using only short video clips. I’ve posted a couple of short clips to a new flickr set, “Japan + Design” which I’ll be filling with video and still clips as I get around to processing the backlog of photos.

There’s no chance of my getting rid of the DSLR any time soon as there’s no substitute for huge glass when it comes to taking good photos. However, I have stopped lugging it around unless I’m intentionally on a trip to take hiqh quality photos as the TGV5 is becoming my “go to” camera for documentation and swipe files.

If you have the budget to buy a production-ready 3D printer, you probably shouldn’t be looking at a MakerBot. Production systems have better resolution, support contracts, schmancy STL conversion software and all sorts of other niceties. The MakerBot Cupcake is not a Stratasys, you’re not just going to plug it in and be cranking out pretty models a few hours later.

However, if you don’t have a huge budget and you’re willing to spend time debugging, tweaking, and generally getting your hands dirty; if you’re ok with the smell of ABS fumes, the stepper motor “songs“, and tending to an occasionally fussy machine that will botch a part for no obvious reason; and if you enjoy hacking and iterative exploration of technology, then maybe you’re the right sort of person to put together a MakerBot Cupcake or other reprap-based 3D printer.

Home scale fabrication is the domain of garage-carpenters and basement-machinists, the MakerBot doesn’t replace either. To some extent, building and running a MakerBot requires some of these related skills. Do you have a feel for how tight you can turn a bolt holding two pieces of wood together before it snaps the wood? Do you know how to shorten a screw with a hacksaw and keep the threads clean? You already own a multimeter, do you have a thermistor probe as well? How are you at diagnosing a wiring problem in a stepper motor?

Of the various reprap-related projects, MakerBot Cupcake is pretty clearly the easiest to put together. I got mine up and running without much fuss, but I’ve been building things from kits or fabbing things from raw materials for many years. I still needed help from the MakerBot mailing list to sort out a couple of minor problems and I’ve been able to help a couple of other people with their problems.

If you’re primarily a designer, there’s a reason you should consider taking the plunge even if you think you aren’t the sort of person who is ready to build their own 3D printer: self-education.

I’ve learned a lot about fabrication working in the opensource 3D printing world that I was never exposed to using commercial systems. Learning how to use Blender to create models has been painful at times, but I find myself liking it more than Solidworks for simple projects. I’ve learned about bad STL code, the relationships between temperature and speed when laying down plastic, and more about the physical properties of ABS than I ever thought I would need to know. Assembling the MakerBot from parts exposed me to a few neat tricks you can use to make 3D objects out of sheets of acrylic, and some new joining techniques for thin surfaces.

This new knowledge is also helping my ongoing education as a designer. Now that I know some of the printing capabilities, I can change my sketching and ideation process to work around limitations or integrate limitations of the printer. I’ve also rediscovered the old metalworking path of designing a mold to create a basic shape that is finished on machine tools, but instead I’m printing 3D plastic that I can finish using hand tools or machine tools.

It hasn’t been the easiest tool I’ve learned to use, but building and using the MakerBot might be the “funnest” tool I’ve learned to use in recent years.

Technorati Tags: hacking, makerbot, reprap

In the 1980s the average person didn’t own a home computer. Those who did were likely to be gamers, hackers, tinkerers, or someone else interested in owning a computer as a hobby, not as an everyday tool. ~30 years later, computers are a part of everyday life, used for paying bills, keeping up with friends, publishing photos, and a whole host of other uses we could never have predicted back in the days of the SE and AT. We knew that home computers would change things, but we couldn’t predict how, no matter how many episodes of Star Trek or Max Headroom we watched on multi-generation VHS tapes copied from friends.

Today, 25 years after the Great Pagemaker Massacre of 1985, we’re on the verge of another massive change in how our world works. I have no idea how that change will manifest itself, but I’d like to be one of the first to find out.

I just built a MakerBot Cupcake 3D printer, which is itself based on the reprap project printers. Since the first question most people ask me is “how much did it cost?”, I’m going to start off this series of notes talking about the economics of 3D printing.

In raw dollars, the Cupcake cost a little less than my first computer, a Commodore C64 with monitor, printer, and omfg, floppy drive instead of cassette recorder, all of which set my parents back a bit over a grand. While a grand or so in the early 80s bought a fair bit more than it does now, like other home computers, you couldn’t just buy the computer. We probably spent another few hundred dollars on software, joysticks, blank floppies, that weird “computer-paper” that the printer used and so on. Most of those things came from third parties, so there was competition to keep the prices down — you weren’t locked into buying blank floppies only from Commodore.

Like the C64, one of the selling points for the Cupcake is that it’s a cheap, no-frills device. Part of the fun in having a Cupcake is the DIY aesthetic of figuring out how it works, why it works, and how to keep it working. Another not so obvious selling point, is that the Cupcake is based on opensource software and hardware. If you’re not familiar with the 3D printer market, you’re probably thinking “so? I bought a cheap PC built from parts and run linux? What’s the big deal about an opensourced 3D printer?”

Commercial 3D printer companies, like most 2D printer companies, operate by selling you the “razor for cheap then making it up on the blades”. The profit isn’t in the printer, it’s in the supplies the printer uses and the support contract to keep it running. Next time you see a really inexpensive inkjet printer for sale, research the cost of a set of replacement ink cartridges. Compare the volume of ink in the cartridges and their price and compare that with the price of refill ink, or look at the effort some manufacturers put into forcing you to only buy new cartridges by using DRM. (There’s an excellent eBay scam that takes advantage of the pricing disparities: buy a printer, pull the ink cartridges, then sell the printer “like new” for near what you paid for it to someone who doesn’t know how much the replacement cost of the cartridges.)

Two things you usually have to buy from the manufacturer if you own a commercial, closed-source 3D printer are the material to print with and the base that you print on. The printing material is probably a spool of ABS plastic in a vendor-specific housing and the printing base is also ABS and also vendor specific. There’s a nice article over at Time Compression that goes into cost details to be considered when buying a commercial 3D printer, but we’ll skip to the chase and say we’re talking about US$ 1-2 per cubic inch on the proprietary systems vs. USD $10 per pound of raw ABS from MakerBot. Oh, and instead of those $5 one-use print surfaces only available from the vendor, the Cupcake prints on a variety of surfaces available at any art supply store, some of them reusable for dozens of prints. (I’ve used a small piece of acrylic for ~20 prints on the Cupcake with no signs of wear and tear.)

This is opposite to how 2D printing has worked going back to the earliest days of printing. Once someone had the idea to cut blocks of wood or cast lead as type, the printer could control costs by simply buying raw materials for the best price they could negotiate and recycling them when possible. Cast some metal into type, then melt it down when you no longer need it. Screw up a print run? No problem, we can recycle that paper. Wore out your wooden printing block? Have someone carve another and get back to printing.

When I learned to type (“yes, grandpa, on a typewrier, we know”) it was on an IBM Selectric that used a ribbon and “typewriter” paper. The ribbon was sold by IBM, but replacements were available from third parties. Likewise, I didn’t have to buy my paper from IBM, I could buy it from any office supply store. I could even buy paper that IBM didn’t approve of (as if such a thing existed). If my typewriter needed repair, I didn’t have to call the IBM tech, I could go to any typewriter repair shop I choose.   

This is pretty much exactly opposite to how 3D printers work now. If you own a FooCorp X1000 you are pretty much locked into buying everything from FooCorp. Having problems with your X1000? Is your support contract paid up? Are you allowed to even open it and try and fix it yourself without violating your contract?

While the Cupcake is opensource, and one is not locked into buying ABS from MakerBot, it isn’t a completely self-sustaining ecology just yet. The first problem is that there’s no way to convert ABS models and scrap back into spools of ABS for printing . The technology to melt and extrude ABS plastic is there, it’s just a matter of someone building a melter/extruder that’s safe for home use. Safety might end up being the real problem as ABS fumes aren’t something you want to breath on a regular basis. Instead of recycling ABS on the individual level, perhaps the local door-to-door ABS recycling firm comes by and trades your scrap for fresh rolls of ABS, similar to the newspapers for toilet paper biz in Japan. One step further would be the ability to take broken ABS items and recycle them into replacement parts. If a knob or some other small part breaks, bring it over to my place, I’ll print you a new one then give the old one to the recycler in trade for more plastic.

So there you have the costs — under a grand and a dozen or two hours of your time to assemble it, adjust it, and get it running. Some of the money you’re “saving” by buying a DIY printer is going to be translated into hours of your time assembling, adjusting, and generally tweaking your Cupcake to get a decent print.   

Next we’ll look at who the real customer is and whether you should buy a Cupcake or just ship your STL to RedEye.

Technorati Tags: cupcake, diy, makerbot, reprap

1) Any ixd doing iPhone dev who needs pixel-precise templates should be able to make their own templates in Illustrator (equiv.) and print them out.  You know what’s better than spiral, lay-flat bindings?  No binding at all!

2) A physical drawing template? Is this 1980? Are we making flow charts?  A template that precise is either proof that you need to learn to draw or that you should be comping on the screen and not on paper. (If you have access to a laser cutter you could easily make your own.)

3) There are these things called “Post-it(tm) Note”s that come in various colors and sizes. They stick to things, say a whiteboard or a clipboard, so you can do things like rearrange navigation or swap out different comps for screens. You should try them, they’re really nifty.

Ok, four thoughts:

4) The reviewer writes: ” My sketching skills are teh suck, so[...]”

Yes, and they will continue to suck until you stop fussing around with templates and learn to draw freehand. I say that as someone who spent years making sucky drawings with rulers, templates, and other drawing “aids” that did nothing save prevent me from learning how to draw.

Technorati Tags: design, drawing, rant

Last week, we bought yet-another-cordless-phone after the GE died and the replacement handset would never sync properly with the base station. This time, I decided to go with a Panasonic, as some similar models had received good ratings in Consumer Reports and Costco had them for cheap.

Setting them up, I was happy to discover that instead of some cordless phone specific battery, they use regular NiMH AAA batteries. Plentiful and cheap when the time comes to replace them.

Now if I could just get a set of schematics and a parts list so we’d have a chance of repairing the phone itself, maybe I’d have a phone that I could maintain over the long run…

Technorati Tags: batteries, design, sustainability

Was I ever wrong.

We still have a full day of presentations to go, and if they’re half as good as today’s presentations, it will still be a total win for this conference. I’ve met lots of interesting people and my head is stuffed with new ideas.

Technorati Tags: interaction 09, ixda

Twitter, however, seems to be the perfect place for those one-liners that people feel free to ignore if they’re busy.

You can follow my “look at it if you’re bored” stream at allartburns.

Technorati Tags: quickie, surfing, twitter

Art That Learns, a class on machine learning and art installations taught by Osman Khan and Carlos Guestrin

Interactive Technologies and Live Performance, a class on technology and performance taught by Golan Levin and Matt Grey.

mTID research, wherein I reveal the invisible.

My fourth studio is an independent study on drawing, I’ll probably scan/post some stuff from that here.

More soon.

Technorati Tags: design, mtid, school

A “time machine” radio that allows you tune into a year instead of a radio frequency.

Technorati Tags: arduino, design, interaction, sketching

Today I was talking to a undergrad who is disillusioned with what he’s studying in industrial design studio.  While we were talking, I was reminded of something Papanek wrote that helped me figure out What I Want to do With My Life.

_Design for the Real World_, a book that got Papanek kicked out of the IDSA, really made me wake up and think about what it is I am doing and why.  The revised edition of _Design for the Real World_ is much better than the original, but the first paragraph stays the same:

There are professions more harmful than industrial design, but only a very few of them. And possibly only one profession is phonier. Advertising design, in persuading people to buy things they don’t need, with money they don’t have, in order to impress others who don’t care, is probably the phoniest field in existence today. Industrial design, by concocting the tawdry idiocies hawked by advertisers, comes a close second. Never before in history have grown men sat down and seriously designed electric hairbrushes, rhinestone-covered shoe horns, and mink carpeting for bathrooms, and then drawn up elaborate plans to make and sell these gadgets to millions of people. Before (in the “good old days”), if a person liked killing people, he had to become a general, purchase a coal mine, or else study nuclear physics. Today, industrial design has put murder on a mass-production basis. By designing criminally unsafe automobiles that kill or maim nearly one million people around the world each year, by creating whole new species of permanent garbage to clutter up the landscape, and by choosing materials and processes that pollute the air we breath, designers have become a dangerous breed. And the skills needed in these activities are carefully taught to young people.

Technorati Tags: design, life, papanek

Except that now, RISD is leapfrogging.

For those of you too lazy to go read wikipedia, “leapfrogging” is when you go from being way behind everyone else to being way ahead by skipping everything between “behind” and “ahead”. As an example, instead of ~30 years of desktop PCs and crappy software in schools, kids around the world are going directly from chalk and slate to OLPCs and mobile phones .

RISD is going to do the same thing.

Why?

RISD has Maeda.

There’s a 19th century-like hall of wonders called the “Nature Lab” at RISD, where students can look at something like 80,000 specimens from around the world. Which is a really useful thing to have when you need to study the physical structure of some random animal — why look at a book when you can look at an actual skeleton or taxidermy? Problem being, you need good light to study an object, and the Nature Lab is in a building, not outdoors in, well, nature.

Thanks to Maeda, the Nature Lab has artificial daylight and color adjusting lamps from Zumtobel.

That’s rethinking the education process in action. RISD doesn’t need a fancy computerized database with 3D holographs of everything, they just needed some state-of-the-art lighting in their historic building.

Technorati Tags: design, leapfrogging, Maeda, RISD

I switched to feedburner for my RSS feed since it can do things like include my del. bookmarks and the like.

Initially, I just have it set to pull my del tags once a day.

If it you notice any problems, please let me know.

Technorati Tags: feedburner

I’m the first to admit that I have a problem with constructive criticism. I’ve never been terribly good at gently nudging someone onto the right path with kind words; I’m much better at beating them with a stick when they go down the wrong path. I apologize in advance if this comes off as harsh, it’s really not my intent. I want us to be brilliant, I don’t want to score points by pointing out where people are screwing up.

I recently started reading RISD’s latest blog (yes, they have more than one), “RISD by Design” and my response was something like

“Oh yeah? Well we just updated our website design after 10 years! So there! Ok, well, we updated some of it, like the main page and a couple other things and a lot of the departments and the search engine still have the old style and there’s not much visual coherence across the campus other than.. uh… so, how about those Stillers?”

That’s not much of a response. As a matter of fact, it made me angry thinking about it.

How is it that a university doing leading-edge research in pretty much every domain including Internet technology (ex: CAPCHA) doesn’t have any sort of, “Hey, look at us!” blog or journal at the university level?

Sure, there are some people working on departmental and project blogging, but that’s a local level. Peter Lee has CSDiary that covers the activities of the CS department and Golan Levin has a personal blog where he talks about issues related to teaching and being a good student. CMU Design has a Twitter feed, which is really great for students in Design, and a couple of classes have had per-class blogs.

But where’s our flagship blog, authored by someone from the President’s Office or at least someone in PR? Why were we not one of the first universities to have a major public blog/journal?

Thinking about past organizations I’ve been in, some possible answers that come to mind:

• We don’t have to. Admission to Carnegie Mellon is highly competitive, anyone we want as a student or donor already knows who we are. There’s simply nothing to be gained from investing in some sort of Maeda-like showcase blog.
• It’s not a high enough priority. Various senior people think it’s important, but we have limited resources and can’t do everything we want to do.
• It’s a bad idea. For whatever reason, enough people at senior levels are simply opposed to the idea of having a presence in blog-space that they can block anyone else who wants to make progress in this area.
• We don’t think the contemporary online world is relevant to the education process.

I’d like to think it’s the first reason (“we’re so great we don’t need to advertise”) but on my grumpy days I suspect that it’s one of the latter.

Here’s why.

Last semester I helped with a class called Making Things Interactive. If you go look at the class blog, you might notice that it’s hosted at wordpress.com, not at cmu.edu.

Why? Well, we don’t have any blogging infrastructure at CMU. Nada. Zip.

Individual people have individual accounts on the campus network and some folk have installed blogging software on their accounts. However, the bandwidth limitations are pretty tight as my fellow student Jennifer Gooch found out the hard way. When her project One Cold Hand got national press, her site got hammered and was quickly shut down by IT because it was using too much bandwidth. It took several days to convince people within the system to change her bandwidth limits, during which she ended up moving her site to another hosting facility.

Think about that a second or two: We were getting really good PR on a national level for a student’s work and that student’s account got locked down because too many people found her work interesting.

Of course, many groups/departments have their own computing resources and self-host their servers, but by doing this they’re duplicating effort and wasting resources. In my program there’s a tiny little *nix box sitting in someone’s office running yet-another install of gentoo/apache and some custom CMS software. Why can’t we just fill out some sort of web requisition form and get a wordpress install up and running on a hosted campus facility? I host several sites (including this one) at dreamhost, so I can honestly say that it’s pretty trivial to set up a domain and get blogging software up and running if the basic infrastructure is in place.

In the short term, what we need is a blogfarm running WordPress. We don’t need CS to go into NIH mode and create yet another parallel-but-different-solution, we just need a bunch of blades in racks running wordpress and some support from IT in the keeping-it-running-and-updated department. Even if the Powers That Be don’t get blogging, at least give those of us who do the infrastructure we need to set up and run blogs on local, supported servers.

Once the infrastructure is up and running and people are using it and we start getting attention, we can more easily convince the Powers That Be why blogging/journaling is so important to the future success of our university. If a mere art school like RISD (sorry, cheap shot, I know :-) has a public face in the online world, why doesn’t a cutting edge, interdisciplinary research university like Carnegie Mellon have a public face that’s an order of magnitude better?

I have negative free time to help with this sort of thing, but my program could really use a locally hosted blog/website where we could show off all of our work. Right now I’m looking at setting up something on ning to promote our program and asking my advisor to spend a few $ to make the ads go away; I’m more than happy to help someone who has the time/energy to lead this charge.

So. Time to “shut up and skate”, as we said back in the day. I don’t have time to help build a ramp, but I’m happy to help sweep leaves out of an empty pool.

Technorati Tags: blogs, cmu, risd