Thursday, September 14, 2017

Lifeform scanner...

So it just never seizes to amaze me all the beautiful craftmanship that some members of the forum goes through, to make sure the parts of R2D2 is up to par! So even an R2 detail which mostly is visible in only one of the movies, can be reproduced to such a detail! This is the life-form scanner, from The Empire Strikes Back. 






Result:


Wow, its just stunning!

Each part manufactured may only be available in small quantities and for a short amount of time. Since these are not produced for any commercial use, only in limited numbers for re-sale to members of the forum. So mostly you could scout the forum for the next part-run or start building your own and try to follow the screen accuracy.

R2D2 really is a swiss-army-robot when you look at all his devices!

...I guess collecting piece by piece when available, and see which parts you can make for yourself is one way to go at it...

Finally got it!!!

Special order this week: the 300 mm dome. FINALLY!

Inner dome

Includes Seamless Milled Bottom Ring

This Hydro Dome Part Run includes:

• 1 Aluminum laser cut outer dome

• 1 Aluminum laser cut inner dome: Inner dome laser cuts include, Radar eye mounting holes, 5 Pie panels, 4 bottom panels to the right of the front HP, these panels are cut with large side tabs (for those who want them to remain static), 3 HP Holes, 3 Openings for Front and Rear Logics, dome bump holes, 2 Holes for PSIs. The inner dome includes hardware for mounting to the inner ring.

• 1 Aluminum one piece bottom ring: Includes hardware for mounting the inner dome to the ring.
The ring is pre-drilled for the "Rockler" Bearing and includes stainless steel hardware for spacing and mounting to the Rockler bearing.

This Dome Fits all CS:L and CS:R parts and frames. Fits all Styrene, Wood and Aluminum Frames.






So I was waiting for this rather important part, since may when the build started. Since may we have had a break from building R2, since first we got married, and then we found a house and have been in a moving process for the last 1,5 month. But as things were coming together, Darren Muller suddenly annonced that the R2D2 aluminium dome would be available in september. And here I was, almost pressing F5 daily at the granite earth home page, everyday since June...

http://www.graniteearth.com/ProductDetails.asp?ProductCode=ALUMINUM-DOME-SET

for resale only to members on the Astromech forum, not intended for commercial use, the interest was still sky-high. So these babies were available only 25 minutes or so, on tuesday (yesterday). And on monday Darren sold the last couple of units from the previous design and those units (might have been 5 of them) were sold within 5 minutes.

So getting my hands on one of these, is a dream I have had for quite some time now. It is essential to our build! <3 ..nothing can really compare to a real 300 mm aluminium dome and unfortunately it is not a piece you can really manufacture on your own!

The previous design I had made a post about it earlier, also had a bottomplate which in this design unfortunately is gone. This is because it was a piece of scrapmetal left over from manufacturing the earlier design. But I think we can solve it design-wise. The important thing is that we got the DOME!

I can not stress this enough. We are looking forward to starting assembly on this wonderful piece! <3

Monday, July 24, 2017

Fixing the 3d printer...

So we have come to this... had a couple of weeks we were busy with the wedding and all, and after that a piece of plastic got stuck in my FlashForge Finder and after that I was to lazy to fix the machine. But now I finally got around to clear the machine of this PLA plastic that was stuck inside. 

That happens sometime and is not very uncommon...





Fixed it! Here is a tutorial...


Source: https://www.youtube.com/watch?v=qyEpvwhDKis&feature=youtu.be

Now back to printing! ^^ 

Wednesday, July 19, 2017

Star Wars Wedding...

So we had a slight break in our build, since we went to Paris and got married! Slightly Star Wars themed wedding, we finally got the churches blessing over our marriage! <3






We are superhappy and now that it's all said and done we can resume our build of our R2D2 unit!

Sunday, June 18, 2017

Assemble the wood frame...

We opted for a wood frame, because it seemed like a solid option. We are building according to CS-R blueprints for R2D2,  (revised). We found another member through the Astromech forum that does a run on wood frames. This is made from Ukrainian Birch Wood, exported to USA, CNC-cut and now exported back to Sweden. I guess thats 0-1 for the Climate, but still we got a great looking frame here. I did ask local companies but they did not seem to interested in minimal order of 1 unit, and they just said that I could possible ask local carpenters. So I did ask a couple of those, but seemed busy at the moment.

I guess this was the shortcut instead of cutting the frame ourselves.

If you ignore the RC plane at the far side of the table, the rest of the pieces are our wood frame! :)


Test assemble... we started watching the youtube video I have linked before, but quickly noted that in the video they are using the CS-L frame instead of this one, so we chose to look at the pictures provided by the seller, and we had no problems putting it together.


Fitted, but not glued together...


And ofc we just had to testfit some of our 3D printed pieces so far... 



We did also make a test using cell-foam for filling up parts of the frame which is not needed for eiter details or hatches. We are guessing that it could give some support for the outer-layer-skin and also may give some extra support to the frame and make for a more solid construct. This kind of cell foam doesn't really add any extra weight to the R2 unit.


That's all for now...

Friday, June 16, 2017

3D printing tools...

We have a lot of sanding to do, so one step is to find ways to sand effectively in all the angels. So this is an example of what to do. Olof Geelnard designed this for our use on the R2D2 unit. This is designed at https://www.tinkercad.com/


And this is the printed result, lower polygon count at the bottom to have a better grip when inserted, and the highest resolution at the top, so that is quite solid and sterdy:




And this is how it works...


Wednesday, June 14, 2017

R2-D2 Builders Club...

Apply for your membership: http://astromech.net/forums/forum.php



With a members counting at around 40.000 persons, there is a lot of knowledge available at the Astromech forum. Free membership, easy to join! :)

Sunday, June 11, 2017

Death Star plans...

I guess an R2 unit really should have a copy of this file...   just for screen accuracy!




Source: https://www.youtube.com/watch?v=VgpTHHP-WSA

Help me Obi-Wan Kenobi, you are my only hope...



Something like this, to put on a projector screen from our R2D2 unit perhaps? This is Rob Meyer's re-edited Leia message. He actually captured the scene and then edited it frame-by-frame  in photoshop. A crude way, but effective way. https://www.youtube.com/watch?v=tf-1xeE3zzE

Filler and sanding...

Apart from 3D printing alot of pieces there is also all the work with perfecting every part after printing is done. We chose to do all the prints in high-resolution to make it easier to make a nice finish...




R2D2:s arm from the front, there is suppose to be two of them. These are composed of 3d prints that are made in four seperate parts, then glued together. There is a lot of sanding, filler spray, sanding, then more filler spray, several layers...

so there is four parts on each arm, they are printed two at a time, And there is three pieces of sort of like a box, where the arm is folded inside, which are also printed. These three parts (not shown in picture) also takes around 8 hours each, to print in high resolution, and these arms have about 14-16 hours of printing in them already. And that does not include all the work that goes into perfecting the object afterwards...

This is sort of like half way through the process! A lot more hours to go!

Saturday, June 10, 2017

Attaching servos to the holo lenses...

So we were really wondering about an effective sollution for the attachment of servos to the hololenses. Just attaching them directly to the 3D printed hololens-part didn't really sit that well with me.

Today I saw this, as another member at the forum, Mowee has made this great printable frame! And it's available as an .stl file through the Astromech.net forum!




It never stop to amaze me, how wonderful this hobby is with all the engineering details, little projects that the community seem to find nice sollutions to, one piece at the time...

Friday, June 9, 2017

Just received the Teeces lightsystem...

...and now it's fully operational! Here we have added some temporary frames just to test out the system but it seem to be functioning just fine!


We are really happy with the way it has turned out! The frames we have 3D printed, the tubes are pvc piping, so we got those together with the light-kit. The logics run off of a arduino, and Curiousmarc has originally written the code!



Just some close-ups!

Thursday, June 8, 2017

Running the dome...

Just looking at others solution for the dome... basically it goes something like this:





...and that is what makes the dome able to spin around and around and around... the bolts can't be to long as they will hinder the movement as you place it on the slipring.

The engine you can find here but also at alot of other places too:
https://www.amazon.com/12Vdc-Right-Angle-Drive-Electric/dp/B005IR1NBA/ref=sr_1_5?ie=UTF8&qid=1421189468&sr=8-5&keywords=seat%20motor

But there is some assembly required, so here is a basic tutorial from youtube:


Noted is that we will probably go in a different direction since these kinds of engines can be a bit loud, they have a high-pitch...so some kind of high-torque engine, we will get back to you on that one as we look into other solutions... 

R2D2 electronics sketch...

Basically the Marcduino set-up goes something like this! Teeces lightsystem and 16 servos to control the dome functionality with all hatches open and close, two servos to each holo-lens, and a wifly socket because Marcduino has his own app for running the R2 unit. Extremly well-written program if you ask me!

Basic sketch:



Here Marc demonstrates the R2 touch - app, available at the appstore, and more currently also for android as I have heard! We are going to see if we can get this kind of functionality into our R2 unit because when someone already made a system with high-functionality it would be kinda stubborn to develop another system that would be far worse. If the support ends for this app we will make our own controller though.



We are also currently looking at different motors for the feet-drives. An Astromech can weigh about 60 kg so there is alot of weight to pull around!

Wednesday, June 7, 2017

Testing Arduino...

This is an easy assembly from a Arduino Uno kit, trying out the code just for fun and see how the system works. Mostly because I hadn't tried it before.

Basically connect like this:



/*
*
*
*/
#include <LiquidCrystal.h> // includes the LiquidCrystal Library
LiquidCrystal lcd(7, 8, 9, 10, 11, 12); // Creates an LC object. Parameters: (rs, enable, d4, d5, d6, d7)

int backLight = 13; // set pin 13 to control the backlight;

void setup() {
  // put your setup code here, to run once:

 lcd.begin(16,2); // Initializes the interface to the LCD screen, and specifies the dimensions (width and height) of the display }
 lcd.print("hello, world!");

 pinMode (backLight, OUTPUT);

digitalWrite(backLight,HIGH);

lcd.clear();

lcd.begin(16,2);

lcd.setCursor(0,0);

lcd.print("Hello, World"); // can change any words you want;

lcd.setCursor(0,1);

lcd.print("I feel good!"); // can change any words you want;

}

void loop() {
  // put your main code here, to run repeatedly:

 delay(3000);
 lcd.clear(); // Clears the display

 lcd.print("Arduino"); // Prints "Arduino" on the LCD
 delay(3000); // 3 seconds delay
 lcd.setCursor(2,1); // Sets the location at which subsequent text written to the LCD will be displayed
 lcd.print("Makes magic");
 delay(3000);
 lcd.clear(); // Clears the display
 lcd.blink(); //Displays the blinking LCD cursor
 delay(4000);
 lcd.setCursor(7,1);
 delay(3000);
 lcd.noBlink(); // Turns off the blinking LCD cursor
 lcd.cursor(); // Displays an underscore (line) at the position to which the next character will be written
 delay(4000);
 lcd.noCursor(); // Hides the LCD cursor
 lcd.clear(); // Clears the LCD screen

 }

I did not clean up this code, so use it for what it is, just a test! 

Some of our 3D prints so far...

Basically we got all the files to 3D print an entire R2D2 if we wanted to, but in our view of things, it just feels slightly wrong to 3D print all of it, so we will go for a mixture of materials. Right now though, some of our 3D prints have actually turned out pretty well!

Here is one of the holo-lenses from R2D2:s head:



We are using Simplify3D for slicing the 3D model files, made by Michael Baddeley who can be found through Thingiverse at https://www.thingiverse.com/mrbaddeley/about or through Facebook or the Astromech.net forums. He has been kind enough to opensource his files, through the forums and R2 builders community.

These are made with Ultimaker 3, and high resolution print, about 22hours printtime, but the details are looking sharp and good.


Large logic (rear) on the Dome, in high-resolution, printed on a Ultimaker 2 with high-resolution settings from the Simplify3D slicer.


This is made on a Forge Finder SE, with the same high resolution settings, about 14 hours printtime. We decided to go for High resolution on all details, even though it makes every print about two to three times longer. But the quality of the prints are really worth the wait!

Soldering or tinkering...

We also had a look at curiousmarc's sketch-up for running the droid on specific arduinos, called "Marcduino" cards. They are adapted Arduino boards specifically designed for the use of droid-control, servo, coordinated light and sound effects and so on!

There is always the option of building an entire new system, and there are some other systems that are widely spread throughout the R2D2 builders community.




Basically it is possible to order these cards off a site called Oshpark, https://store.oshpark.com/
they do keep alot of neat stuff, but there is some work to be done as is to be seen in the second picture.

Some of the R2 builders use what they call, SHADOW together with a Padawan 360 system, which is infact using a Playstation 2 or XBOX controller to actually manage the droids technical systems. We have a background in regular RC flying and cars so we will go for a more traditional sollution with RC controllers but also Arduino or Marcduino to manage some of the electrical systems.

After actually putting the cards together there is ofcourse the actual code to be written onto these cards. ,,,babysteps. Marc does keep some very useful information on his website. If this is the system we are going to use or not. Well, time will tell. We got the cards, so it is a definite option.

For now, we are looking at how to interconnect the light&sound system with dome automation, and also the mechanics for the feet-drive of the R2 unit.

R2D2 lights...

Actually lighting the dome can post quite a challenge. Luckily there are some sollutions to the problem. One is to use a club-specific light-system. Teeces, which was developed by a member of the forum who goes by the name "curiousmarc" at the forum.

He has an excellent webpage where he explains his build of his R2. Also, he explains the Teeces system: http://www.curiousmarc.com/teeces-logics-dome-lights


This poses an excellent choice for us!

3D printing R2D2...

We also quickly discovered that a lot of R2D2:s parts are not easy to come by. This is because they are either made in aluminium for R2D2 builders, or they are cast in resin, or 3d printed. 

Getting the parts from Ebay would be extremly costly, as browsing the internet showed us. Aluminium parts are still the most expensive, but also the molded resin parts are quite expensive as they are made by hand, one at a time and R2D2 has alot of parts that you can't make by yourself.

So early in the process we looked at 3D printing as an option, to be able to do some of the parts at home. There is a nice community that shares 3D print files and if you have the access to a 3D printer you will be able to make these parts by yourself.


Flashforge Finder (SE) is a nice alternative for home printing, not a heated printbed though and only 14x14x14 building area posts some challenges.

Lucas Arts has the copyright of the R2D2 creation, but since the R2 builders club, doesnt sell these droids for money, and use them for charity. It has not been a problem within the community to build your own droid! At https://www.thingiverse.com/ you can find some parts, as an example. Within the community you could probably find more...

We also have taken contact to our local MakerSpace LuleƄ, and they also have a couple of Ultimakers 3D printing machines at their facilities, so we can also use them for some of our bigger prints.


3D print of R2D2 radar eye, turned out very nicely!

Basic structure of body...

We opted for a wood frame, although there is many routes to go. Some make their R2D2:s out of aluminium frames, (extremly expensive), wood, or a total 3D print is also possible since 3D printing as become a tool available for the masses.

We decided that we wanted a mix of materials, so therefore a wood frame seemed like a solid choice. There are many way to vary this choice aswell. Also a member of the R2D2 builders club has made plans for a wood frame that is also available through the R2 builders club, so either you can cut MDF or plywood by yourself or you can pre-order a frame and then assemble...

This is a "lazy-susan" basically what makes R2D2:s head able to spin in circles... the dome will rest on top of this.







Basically a wood-frame kit that looks somewhat like this as it arrives! We are looking forward to start putting our R2 unit together!

The plans are available here: http://www.midwestr2.com/Images/SennaTemplates.pdf
...or just scout the Astromech forum since they have all the building plans for your R2D2 unit.