3D Printing Filament from Recycled Car Dashboards

logoThe Netherlands is back at it again!  This time, it is a company named Refil.  What Refil is currently doing is recycling old car dashboards and used plastic bottles into new 3D printer filament.  Currently they offer 2 types of filament, black ABS, and translucent PET.

The black ABS is made from 100% recycled car dashboards, door panels, and other ABS car parts.  The translucent PET, is made from 90% recycled plastic bottles.  What is really cool about the translucent material, is that the color is unique to whatever type of bottle that they happen to be recycling that day.  Which means it could be greenish, clearish, blueish, grayish.  Very cool.

This company makes this filament by grinding up the original material, melting it down, removing any impurities or contaminants, and finally extruding it in either 1.75mm or 2.85mm 3D printing filament.

Currently, the price to ship this filament to the US, it a bit steep, but we plan on getting our hands on some of this soon to give it a try.

Check out their website at http://re-filament.com

Posted in 3D Printing

Stainless Steel PLA for FDM 3D Printers!

20150430_103630No really, I did not believe it at first either. Proto-Pasta has done it again with another crazy filament!  They have officially created and began selling a stainless steel and plastic composite that can be used successfully in FDM 3D printers.  Obviously, I had to get my hands on it and give it a try.

Once I received my 500g spool, the first thing I noticed is that Proto-Pasta has created a 100% recyclable spool out of heavy duty cardboard.  This is great!  It is really nice to see companies like this thinking more about the big picture.  So I loaded the filament up in our Ultimaker Original Plus and began the test print robot.  On the spool it said to set the heated bed temp to 50c, but a heated bed was not required.  So, I went ahead and followed directions and set the heated bed accordingly.

The filament was flowing very nicely at about 220-225c at a layer height of 120 microns.  It printed just like any other PLA.  Unfortunately, half way through the first print, the robot dislodged from the heated glass bed and I had to stop the print.  The reason this happened was because the heated bed was not hot enough to hold tight to the part.  I cranked the heated bed up to 70c where I like to keep it for PLA and started again.

20150430_203458The second print finished great!  It held tight to the heated glass platform and printed very nicely.  This stuff is definitely heavy and feels like a cast metal part.  This material is obviously not as strong as metal, but it does give the appearance and feel of cast metal.

My final thoughts on the filament are that it is definitely a neat material for people looking to make things like sculptures, but I think this could be very useful to create parts that need to be heavy and have low impact requirements.  This material is also pretty expensive at the moment, but I can see this coming down in price as the technology matures.

Posted in 3D Printing, Filament Reviews

New Danesi Designs Product Page

We are pleased to go live with our new Products page.  Here you will find information and purchasing links of our current and future products.

products page

Danesi Designs new Products Page snapshot. April, 2015.

Posted in Announcements

Day One Pinball – ScoreGasm Master

4466ce83dd5c3775a28b8df7d4a3313eDay One Pinball is proud to announce their first machine!!!  We are very honored to have been part of this project.  Check it out at the links below.

Pinball News Article: http://www.pinballnews.com/news/scoregasmmaster.html

Day One Pinball Website: https://www.dayonepinball.com/

Posted in Pinball

3D Printing, The Good, The Ugly

Hey Everyone,

We have been doing a lot of 3D printing over the past few months.  We have been printing for clients, for fun, and for experimentation purposes.  I figured I would share a few pictures of some of the good and the ugly prints we have encountered.

20150328_134036I am going to start with a beautiful failed print.  This is what we in the industry call, “making spaghetti”.  If the print comes loose from the build plate during a print, this is what you get.  This can occur due to a number of things like fingerprints on the buildplate, or in my case, improper part cooling of the part during printing.  What happened in this scenario was that I disabled the nozzle cooling fans during the print and the part warped a bit at the top causing the nozzle to hit the part and dislodge it from the build plate.  The printer has no idea that this happened and it keeps on going on it’s merry way and ruining your 25 hour print about 20 hours into it.  🙂

20150327_121146This next picture is one of the new experimental materials that we got in.  It is called “Thermoplastic Polyurethane”.  This is the same material that they make roller coaster wheels from.  How cool is that?

I decided to print a test robot using the Ultimaker Original.  This material needs to print at a pretty high temperature.  Somewhere between 240 and 260 C.

So, how do I think it turned out?  Poorly actually.  You can see that the the finish is a bit bubbly.  This is most likely due to me running the extruder too hot at 250C.  You will also notice that the antennas on the head of the robot melted pretty significantly.  This was due to the fact that I did not have the cooling fans running during the print similar to when printing ABS.

Overall a very interesting material.  I could see it practically used as a material for custom mouth guards or something like that.  This material also has an extremely high resistance to abrasion and is relatively flexible.

Now to wrap this up, here are a few pictures of the things that we designed and printed for the 2015 Pinball Olympics!  And, yes, that is a pinball flipper with a neodymium magnet in it.

20150219_141958 20150228_184149 20150305_214805 20150306_205122

Posted in 3D Printing

New LED Driver Board in Development

iWe are excited to announce a new project that we are currently working on. The SDTINY85 is a small development board for the ATTINY85 AVR Microcontroller. This board can be used to house logic to drive up to 3 LEDs or 3 separate lines of logic to an external driver board. The board can be used also as an ATTINY85 programmer as it includes the ISP6 interface to the chip.

The SDTINY85 is also production ready and includes a 5 volt regulator that accepts DC input anywhere from 7-20 volts.  This board is currently designed for output, but the outputs can easily be used as inputs if needed.

More info coming soon!

Posted in Circuit Design

Danesi Designs Shapeways Shop

208x156_3139261_9076256_1424055446We are proud to say that we have opened our Shapeways shop and have begun loading some of our public designs to the website.

What is Shapeways?  Shapeways is the leading 3D printing marketplace and community, empowering designers to bring amazing products to life.  By giving anyone the ability to quickly and affordably turn ideas from digital designs into real products, Shapeways is fundamentally changing how products are made and by whom.


208x156_3140620_9081798_1424099315How is Danesi Designs utilizing Shapeways?  Although we already have 3D printers in house, we would like to open our designs to the public so that when create something interesting in house, others will be able to order it through Shapeways and get a copy of the physical object for themselves.  Obviously our client work will not be posted on Shapeways, but we are always building new and exciting things that we will be sharing.

We are still in the process of loading some of our designs to the store, so the catalog will grow over time.

Danesi Designs Shapeways Store: https://www.shapeways.com/shops/danesidesigns

Posted in 3D Printing, Pinball

Carbon Fiber Building Blocks

So we love to try out new experimental 3D printable materials. We recently got in a roll of Carbon Fiber reinforced PLA from a start-up company called Proto-Pasta. More info can be found at the Proto-Pasta website.

We decided to print a few tests using this new material.  What did we print?  This was an easy question with an obvious answer.  The model of choice ended up being an “unnamed brand” one of our favorite style of building blocks from our childhood!

The images below were printed at 160 micron layer height at 225 degrees C.

20150201_130742 20150201_130807

The material printed quite well, just like any other PLA, but we did notice that the filament was fairly brittle while it was on the spool, so extra care is needed when loading it into the machine.  The bridging performance was really great as well.

As for the overall strength after printing, this is still to be determined.  The material is VERY rigid, but at the same time feels like it could take a bit of an impact without breaking.

Overall, this is a very interesting filament with a nice shiny dark gray appearance.  You can actually see the very small fibers.

We have yet to determine practical applications for this material, but over time will will perform a few more tests.  This could be a very good option for certain types of brackets and tools.

Posted in 3D Printing

Trilogy Beer Pinball and Custom 3D Printed Parts

68833-iIf you have not yet heard of Trilogy Brewing Company, they are a small hobbyist brewing company based out of southern Wisconsin.  Owned and operated by Doug Manley, this brewing company makes more than just great tasting and quality beer.  A few years ago Trilogy Brewing created a pinball machine based on a 1978 Bally Star Trek machine (code name Trilogy 1), that actually serves beer if you are able to beat a certain score.  This machine was hand built, designed, and painted by Doug with minimal outside help.  Doug did all the artwork for the playfield, backglass, and cabinet.  Not to mention all the mechanics and craftsmanship involved with building the lower cabinet from scratch and installing a “kegerator” into the back of it.  Simply amazing.

Doug has recently decided to build 2 more Trilogy Beer pinball machines in which he started in early 2014.  These 2 machines will be similar in design to the original Trilogy Beer pinball machine, but will be based on the playfields from a 1980 Stern Flight 2000.  They will both serve beer and have 100% custom artwork just as the original, but these versions will be keeping their standard alphanumeric score displays.  I cannot wait to see the final results.

More information including detailed pictures of the machines can be found here:

20141228_182311Doug has recently been looking to put a few more customized parts in these 2 “second generation” machines.  This is where we decided to help out and design and print some custom beer barrel star posts for these machines.  The picture to the right is a simple prototype of our beer barrel star post design.  These parts will be printed in PLA with a 30% fill and will be more than strong enough to take the abuse from the environment inside a working pinball machine.  The posts will eventually be printed in a wood color or hand painted to look more realistic.  We may even experiment printing them in actual wood.  Updates on that coming soon…


20140709_110353 (1)We have also supplied Trilogy Brewing Company with a half barrel toy for the 2 new machines with the Trilogy Beer logo built right into it.  This toy is for decoration purposes and was printed in PLA as well.  Doug plans on hand painting these half barrels to resemble aged wood.





If you have any questions about Trilogy Beer or the work that we did, please contact Scott here.

Posted in 3D Printing, Pinball

3D Printing Sparks Pinball Revolution

pinballRecently a few pinball enthusiasts (including Scott Danesi) were contacted by Jason Compton regarding how 3D Printing has changed the evolution of the pinball hobby.  The article was released in early October of this year.

Please check it out!  He also has a bunch of other interesting things on his blog as well.


Posted in 3D Printing, Pinball