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Whitepaper update

This commit is contained in:
Matt McWilliams 2025-04-28 19:48:00 -04:00
parent eeeed38b56
commit 9a1cf17bf8
7 changed files with 899 additions and 31 deletions
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@ -104,7 +104,7 @@ This allows for the tracking of changes over time, with notes annotated why they
Using a human-readable design format means that even if the software for rendering the printable models no longer exists or no longer works or for some reason cannot be executed, the features of the design can be theoretically preserved and recreated by reading the measurements the code describes.
Dimensions and makeup of each part are stored in such a way with adjacent comments and other semantic signifiers to describe the 3D objects in such a way that a person with the OpenSCAD code printed out on paper could reconstruct or recreate in another CAD software or physically.
In the below code example a cube measuring 4 mm x 5 mm x 3 mm has a cylindrical void with a 1.5 mm radius removed from it via the "difference" boolean operation.
In the below code example a cube measuring 4mm x 5mm x 3mm has a cylindrical void with a 1.5mm radius removed from it via the "difference" boolean operation.
```{=latex}
\begin{center}
@ -117,7 +117,7 @@ In the below code example a cube measuring 4 mm x 5 mm x 3 mm has a cylindrical
```
The ultimate goal of this project is to create a free and open design that is a platform others can expand on to fulfill their production needs.
The goal is *not* to create a product and take on all of the expectations and economic considerations that endeavor requires.
The goal is *not* to create a "product" and take on all of the consumerist expectations and financial considerations that endeavor requires.
The licensing of the project allows for the possibility of motivated individuals or organizations to produce and sell the contact printer without any restrictions.
That same license also gives people the ability to create their own modification and release their own design as they see fit.
@ -166,9 +166,19 @@ The ultra-cheap resin printer used in prototyping this sprocketed roller is the
This can be compared to the resolutions available in the FDM printer used to make this prototype, the Creality Ender 3 [@ender3], which extrudes plastic through a 400 micron (0.4mm) nozzle and has a range of vertical and horizontal resolutions from 100 to 300 microns (0.1mm to 0.3mm).
The reason these resolutions are important is because of the specification for 16mm perforations on film.
Perforations for 16mm film are standarized at 1.27mm high by 1.829mm wide with 0.01mm tolerances [@perforations].
Printers that can only produce parts at a resolutions that is 10 to 40 times larger than the tolerance for the standard limits the ability to accurately produce useful sprockets.
SLA printing puts production within the correct scale.
```{=latex}
\begin{center}
```
![Illustration of the 8-frame sprocketed roller and the 18-frame roller created with the same module]()
![Illustration of the 8-frame sprocketed roller and the 18-frame roller created with the same module](../img/contact_printer_roller_comparison.svg){ width=4in height=2.42in }
```{=latex}
\end{center}
```
Development of this sprocketed drive roller was kick-started by using an existing parametric model[@param-roller] that was designed to replace an 8-frame roller and work on this project was up-streamed into that module so that it may benefit other use cases.
That work has already proven useful to the mcopy [@mcopy] project as the updated module has been used to design a gate compatible with JK optical printers.
@ -221,7 +231,7 @@ This reduces the overall cost of the build and removes the need for additional m
The take-up mechanisms for the picture and stock are inspired by a feature in the The Shaffer Linear Processor [@slp]: the magnetic clutch [@slp-clutch].
In principle a magnetic clutch is two parts; one is driven at a constant speed and a second part, secured only by magnets, slips while tension against it is too great to allow it to move.
The design in this project uses 6 mm neodymium magnets on a drive wheel attached to a coupler with a steel washer and a square pegs for film spools and core adapters.
The design in this project uses 6mm neodymium magnets on a drive wheel attached to a coupler with a steel washer and a square pegs for film spools and core adapters.
```{=latex}
\begin{center}
@ -255,7 +265,9 @@ The solution of raising the brightness of the lamp allows for more color filters
The L298N motor controller module provides a stable 5 volt DC signal that is used for powering the ESP32 and is wired via a transistor to power the lamp.
In theory, the signal provided by the ESP32 to the transistor could be modulated with a PWM channel.
The reason this is being avoided at this stage is that PWM, as in it's name, pulses light to achieve perceptual brightness.
The reason this is being avoided at this stage is that PWM, as in it's name, pulses light for a specified width (or length of time) to achieve perceptual brightness.
Put more simply, PWM is a way to control *perceived* brightness by turning the LED on and off very quickly.
In the case of a continuous contact print, this would mean the light would be, essentially, flashing on and off as the film passed by the gate.
Using a standard Arduino PWM rate of 5 kHz and assuming the printer is running at an ideal 24 fps (24 Hz) means that the LEDs would blink on and off ~208 per frame.
What this *could* result in is 208 distinct lines along the vertical axis of the image.
@ -291,7 +303,16 @@ For a print to be made with sound the gate must allow for a clean separation bet
Sound bleeding into the picture area can affect one side of the image and image bleeding into the soundtrack area can cause a 24Hz hum or other distortion to the audio.
For this reason the standard picture gate and the soundtrack gate should be able to allow light from the lamp to pass onto areas of the film stock that they isolate from one another.
![Illustration of the picture and soundtrack gates side by side]()
```{=latex}
\begin{center}
```
![Illustration of the picture and soundtrack gates side by side](../img/contact_printer_picture_sound.svg){ width=4in height=2.42in }
```{=latex}
\end{center}
```
An example process for making a print with an image and a soundtrack negative would be to run the unexposed, undeveloped print stock with the negative film containing the negative while using a picture gate and then rewinding the print stock and running it again with the soundtrack negative and the soundtrack gate.
This would first expose the picture onto the print stock and then, without developing, add the soundtrack to *only* the soundtrack area of the print.
@ -301,8 +322,8 @@ It is a relatively simple process but it requires precision in the gates to ensu
## The Frame
Within reason, the aluminum frame for this project is resizable.
The first draft of the original prototype was made to support 100 foot daylight spools and was 300 mm by 175 mm (11.8" x 6.9").
This was changed increase the dimensions to allow for 400 foot reels and is now 400 mm by 260 mm (15.75" x 10.25").
The first draft of the original prototype was made to support 100 foot daylight spools and was 300mm by 175mm (11.8" x 6.9").
This was changed increase the dimensions to allow for 400 foot reels and is now 400mm by 260mm (15.75" x 10.25").
Being able to reduce or increase the area of the frame is one way to make it easier to modify and customize tools built using this platform.
There is nothing preventing the creation of a version of this printer with a much larger footage capacity by expanding the frame even further.
@ -341,20 +362,57 @@ Physical interfaces are another area of future expansion and development.
Requests have been made, for example, to add a dial for controlling lamp brightness.
This was avoided in the prototyping phase because it would add parts to the bill of materials and create additional potential points of failure in the wiring.
A simple but robust web interface could be added to control variables for each print: drive motor speed, number of frames to print before stopping, number of frames to run before striking lamp and others.
It could also easily show statistics on each print such as actual speed, variation over a run and other information which would highlight any particular issues.
With the ESP32 platform the printer could be set up as a standalone Wifi access point (like a router) so that devices can connect to it like clients and allow the web app to be accessed from the connected device.
It could also be set up as a Wifi client and exist on a local network and be connected to by any other device on the network with access to it.
Bluetooth is another option as the ESP32 board has dual radios for both Wifi and BLE.
This could control the same variables as a web app could but be connected to by a native mobile application or a web app on a browser that supports the Web Bluetooth API [@web-bt-api].
There is no reason that both web and BLE features cannot be developed in parallel to have matching APIs to allow the greatest number of clients to connect, the only consideration that should be made is that these features not impact performance-heavy actions such as printing.
Introducing delay into, for example, the PID calculations could cause speed fluctuations that would result in uneven exposures on prints.
## Sound
Creating a sound camera from this platform is
The traditional process of making a soundtrack negative for contact printing requires a separate strip of film and often an expensive service that is not available everywhere.
Creating a sound camera from this platform is a secondary goal that has been factored into the design from the early stages.
In practice, this would require creating a alternate lamp or entire panel that would replace the lamp and gate with new module consisting of a exciter lens from an Eiki or B&H projector and an "opt-snd" [@spudic-device] digital sound camera.
Being able to print image and stripe a soundtrack onto the same piece of print stock using a digital audio file would reduce, tremendously, the steps and materials needed to make sound prints.
While discussing this with others, it was suggested that a fly wheel mechanism, like a projector uses, may be needed at the point the sound is written to film.
This may, or may not, be required because the purpose of the fly wheel in a projector is to dampen the intermittent motion of the projector on the film strip as it passes by the exciter lamp and sound reader.
This design is *not* an intermittent motion printer and if the speed of the drive motor is constant enough then the sound should be written without much distortion.
## Color Lamp Control
A digitally-controlled color-changing lamp is an appealing and plausible goal.
RGB LEDs are everywhere and easy to program.
Consider first that PWM is the most common method used to control affordable RGB LEDs.
The aforementioned concerns about PWM duty rate must be addressed for this feature to take shape.
Consider that as a typical RGB LED package that is controlled via PWM by flickering the red, green and blue LEDs at different pulse widths to change the perceptual color.
Sometimes a low-level controller chip will change the individual color channel rates, as well.
This means that, similar to the issue with "white" LEDs creating lines on a print, in a color printing scenario there could be horizontal lines of different colors that are noticeable across the frame.
The ability to track per-frame position also makes features like this attractive.
An idealized system could enable films to be printed with each frame a different lamp value.
This is an incredible idea but requires control and accuracy that are very difficult to achieve with a DIY project.
It is within the realm of possibility but it is firmly in the world of future work for the reason that it goes beyond the standard use case for a desktop contact printer which is to make a work or release print from a single roll of negative film.
## Multi-format
There is nothing, in principle, in this contact printer platform design that would prevent it from being adapted for other movie film formats and there is precedent.
The Kinograph DIY scanner project [@kinograph] presents an example of a 3D-printed multi-format sprocketed roller capable of transporting 16mm, 8mm and 35mm gauge film material.
This is a possibility to consider, though it would introduce new design challenges.
First would be the need to create new lamps and gates for each format.
The take-ups would have to have their spindles extended to support 35mm cores and the idle rollers would have to be enlarged for the same
Next would be the question of speed and the resulting exposure.
Could the drive motor be slowed or sped up to allow for these formats to print properly?
There is also the question of need: is it necessary to create an 8mm gauge printer at all?
8mm gauge print stock is rare if non-existent though there is, in theory, the capability to slit and re-perforate the stock as is done for the Double 8 and Super 8 formats.
### Research Supporters

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@ -22,11 +22,11 @@
<p>A modular design strategy compared to a monolithic one has two theoretical benefits; it can leverage existing components to make the process easier and it can lead to the creation and update of new components that can benefit other projects. Key common elements of a contact printer are the film-transporting sprocketed roller and the motorized film take-ups.</p>
<p>Designing all the printable hardware in OpenSCAD<span class="citation" data-cites="openscad"><sup>3</sup></span> gives the creators the benefits of working with code-managing tools and using only plaintext files. The source control software git<span class="citation" data-cites="git"><sup>4</sup></span> provides the ability to make and track changes that update the project incrementally. Git is a distributed version control software which means that all copies of the design repository contain the entire project history and the entire project can be restored from one copy. Changes that are made and “committed” to the git repository are stored as “diffs” or just the difference between the new code and the previous state. This allows for the tracking of changes over time, with notes annotated why they were made and what they address, and provides the ability to roll back changes to earlier versions of the project.</p>
<p>Using a human-readable design format means that even if the software for rendering the printable models no longer exists or no longer works or for some reason cannot be executed, the features of the design can be theoretically preserved and recreated by reading the measurements the code describes. Dimensions and makeup of each part are stored in such a way with adjacent comments and other semantic signifiers to describe the 3D objects in such a way that a person with the OpenSCAD code printed out on paper could reconstruct or recreate in another CAD software or physically.</p>
<p>In the below code example a cube measuring 4 mm x 5 mm x 3 mm has a cylindrical void with a 1.5 mm radius removed from it via the “difference” boolean operation.</p>
<p>In the below code example a cube measuring 4mm x 5mm x 3mm has a cylindrical void with a 1.5mm radius removed from it via the “difference” boolean operation.</p>
<figure>
<img src="../img/openscad_example.png" style="width:4in;height:2.22in" alt="" /><figcaption>Illustration of OpenSCAD code next to a rendered model of what that code produces</figcaption>
</figure>
<p>The ultimate goal of this project is to create a free and open design that is a platform others can expand on to fulfill their production needs. The goal is <em>not</em> to create a product and take on all of the expectations and economic considerations that endeavor requires. The licensing of the project allows for the possibility of motivated individuals or organizations to produce and sell the contact printer without any restrictions. That same license also gives people the ability to create their own modification and release their own design as they see fit.</p>
<p>The ultimate goal of this project is to create a free and open design that is a platform others can expand on to fulfill their production needs. The goal is <em>not</em> to create a “product” and take on all of the consumerist expectations and financial considerations that endeavor requires. The licensing of the project allows for the possibility of motivated individuals or organizations to produce and sell the contact printer without any restrictions. That same license also gives people the ability to create their own modification and release their own design as they see fit.</p>
<h1 id="spectral-residency-at-filmwerkplaats">SPECTRAL Residency at Filmwerkplaats</h1>
<p>Motivation for this contact printer was spurred on by the SPECTRAL project–Spatial, Performative &amp; Expanded Cinematics – Transnational Research at Artist-run Labs.<span class="citation" data-cites="spectral"><sup>5</sup></span> As a part of the SPECTRAL project, Filmwerkplaats proposed a device research topic: creating a DIY contact printer. In order to fulfill this research proposal the lab hosted a residency with myself, Hrvoje Spudić<span class="citation" data-cites="spudic"><sup>6</sup></span> and Nan Wang.<span class="citation" data-cites="wang"><sup>7</sup></span> We were given time and resources to explore our various topics of research related to contact printing and creating sound prints. This allowed for tremendous progress to be made on the details of the implementation and, with darkroom access, gave opportunities to run tests on exposure, use of filters and overall film tensioning.</p>
<p>This residency took place during The results included a 100 foot sound print made from a Kodak 7222 Double-X negative onto Kodak 3302 print stock, with a soundtrack written directly on the print and a working first draft prototype of this design. Collaboration with the other residents led to ideas for future work and improved the design as we performed tests collectively. The possibility of making this platform work as a soundtrack camera was also explored during this session.</p>
@ -44,11 +44,11 @@
<img src="" alt="" /><figcaption>Illustration of film registered by sprockets</figcaption>
</figure>
<p>Production of the sprocketed rollers via 3D printing has been made easier and more precise by the advent of SLA resin printing becoming more available and cheap in the recent years leading up to this development process. Resin printing is capable of resolutions not possible with FDM desktop printing by an order of magnitude. The ultra-cheap resin printer used in prototyping this sprocketed roller is the Anycubic Mono 4K<span class="citation" data-cites="anycubic"><sup>10</sup></span> which has a Z axis resolution of 10 microns (0.01mm) and a XY resolution of 35 microns (0.035mm). This can be compared to the resolutions available in the FDM printer used to make this prototype, the Creality Ender 3,<span class="citation" data-cites="ender3"><sup>11</sup></span> which extrudes plastic through a 400 micron (0.4mm) nozzle and has a range of vertical and horizontal resolutions from 100 to 300 microns (0.1mm to 0.3mm).</p>
<p>The reason these resolutions are important is because of the specification for 16mm perforations on film.</p>
<p>The reason these resolutions are important is because of the specification for 16mm perforations on film. Perforations for 16mm film are standarized at 1.27mm high by 1.829mm wide with 0.01mm tolerances.<span class="citation" data-cites="perforations"><sup>12</sup></span> Printers that can only produce parts at a resolutions that is 10 to 40 times larger than the tolerance for the standard limits the ability to accurately produce useful sprockets. SLA printing puts production within the correct scale.</p>
<figure>
<img src="" alt="" /><figcaption>Illustration of the 8-frame sprocketed roller and the 18-frame roller created with the same module</figcaption>
<img src="../img/contact_printer_roller_comparison.svg" style="width:4in;height:2.42in" alt="" /><figcaption>Illustration of the 8-frame sprocketed roller and the 18-frame roller created with the same module</figcaption>
</figure>
<p>Development of this sprocketed drive roller was kick-started by using an existing parametric model<span class="citation" data-cites="param-roller"><sup>12</sup></span> that was designed to replace an 8-frame roller and work on this project was up-streamed into that module so that it may benefit other use cases. That work has already proven useful to the mcopy<span class="citation" data-cites="mcopy"><sup>13</sup></span> project as the updated module has been used to design a gate compatible with JK optical printers. Due to the model being parametric, it can be used in designing film transport mechanisms in other, future projects, and additional improvements to the measurements and tolerances will benefit those projects as well.</p>
<p>Development of this sprocketed drive roller was kick-started by using an existing parametric model<span class="citation" data-cites="param-roller"><sup>13</sup></span> that was designed to replace an 8-frame roller and work on this project was up-streamed into that module so that it may benefit other use cases. That work has already proven useful to the mcopy<span class="citation" data-cites="mcopy"><sup>14</sup></span> project as the updated module has been used to design a gate compatible with JK optical printers. Due to the model being parametric, it can be used in designing film transport mechanisms in other, future projects, and additional improvements to the measurements and tolerances will benefit those projects as well.</p>
<p>The roller designed for this project is distinct from a professionally-oriented machine and is similar to the DIY technique of contact printing using a gang sync block and a flashlight or using a modified editing table as a printer. 16mm gauge film has two different pitches of film perforations: short pitches for camera stocks and long pitches for print stocks. The purpose of this difference is to allow for a camera stock to sit on the inside of a cylindrical roller and the print stock on the outside so that the minute difference in diameter cause the perforations to line up when registered by sprockets.</p>
<figure>
<img src="" alt="" /><figcaption>Illustration of short and long pitch films correctly wrapped around a sprocketed roller</figcaption>
@ -63,16 +63,17 @@
<p>Though this was the decision that was made for the earliest prototypes it will be discussed critically in exploration of future work.</p>
<h2 id="the-take-up-motors">The Take-up Motors</h2>
<p>A contact printer typically requires at least four reels, cores or spools to transport two strips of film. Film must be driven from one side–the feed–to another side; the take-up where it is wound onto a core or spool. For this reason only the take-up side <em>needs</em> to be motorized. This reduces the overall cost of the build and removes the need for additional motor-controlling electronics.</p>
<p>The take-up mechanisms for the picture and stock are inspired by a feature in the The Shaffer Linear Processor:<span class="citation" data-cites="slp"><sup>14</sup></span> the magnetic clutch.<span class="citation" data-cites="slp-clutch"><sup>15</sup></span> In principle a magnetic clutch is two parts; one is driven at a constant speed and a second part, secured only by magnets, slips while tension against it is too great to allow it to move. The design in this project uses 6 mm neodymium magnets on a drive wheel attached to a coupler with a steel washer and a square pegs for film spools and core adapters.</p>
<p>The take-up mechanisms for the picture and stock are inspired by a feature in the The Shaffer Linear Processor:<span class="citation" data-cites="slp"><sup>15</sup></span> the magnetic clutch.<span class="citation" data-cites="slp-clutch"><sup>16</sup></span> In principle a magnetic clutch is two parts; one is driven at a constant speed and a second part, secured only by magnets, slips while tension against it is too great to allow it to move. The design in this project uses 6mm neodymium magnets on a drive wheel attached to a coupler with a steel washer and a square pegs for film spools and core adapters.</p>
<figure>
<img src="../img/contact_printer_takeup.svg" style="width:3in;height:3.98in" alt="" /><figcaption>Illustration of an exploded view of a take-up magnetic clutch</figcaption>
</figure>
<p>The choice to direct drive the take-up is due to the fact that powerful geared DC motors are cheap and available. Driving them separately, rather than using a belt, means that the speed can be controlled individually but that they do not need to. The speed of one take-up can be set to expect a daylight spool but could be adjusted in future work to optimize for a 2 or 3 inch core.</p>
<p>The take-up mechanism was designed as a standalone module that is broken out from the project and lives in its own git repository<span class="citation" data-cites="takeup"><sup>16</sup></span> so that it may be easily included in other projects. This module has already been used in the mcopy project<span class="citation" data-cites="mcopy"><sup>13</sup></span> as a motorized film take-up and feed system for JK optical printers. Improvements to the module during the development of either project–catching defects, adding optional features–will benefit the other.</p>
<p>The take-up mechanism was designed as a standalone module that is broken out from the project and lives in its own git repository<span class="citation" data-cites="takeup"><sup>17</sup></span> so that it may be easily included in other projects. This module has already been used in the mcopy project<span class="citation" data-cites="mcopy"><sup>14</sup></span> as a motorized film take-up and feed system for JK optical printers. Improvements to the module during the development of either project–catching defects, adding optional features–will benefit the other.</p>
<h2 id="the-lamp">The Lamp</h2>
<p>To start this project the goal is to create a simple, constant light source for a lamp. Reducing the number of variables in this part of the design reduces the required cognitive load of using the contact printer. Being able to load film and run it rather than tweak settings a constant-brightness LED-based lamp matches the simplicity the Uhler Cine Printer which had a single bulb that was either dimmed or filtered.</p>
<p>The first lamp consisted of a three (3) 5mm LED and from tests at the Filmwerkplaats residency we determined, through all of our tests, that more light is needed to have exposure headroom to run at the speed we chose. A design with six (6) 5mm LEDs was in the next iteration of the lamp that also allowed for an adjustable distance–the first prototype had the LEDs fixed. Assuming perfect light transmission in the second design, this increases the exposure by a stop and allow for more filters to be used in the case of printing onto color stock. Our tests with color prints indicated that we needed additional filters, which cut exposure, to achieve standard color using these “cool white” LEDs that likely emitted light in the ~6000 Kelvin range (though they were not measured to confirm their precise color). The solution of raising the brightness of the lamp allows for more color filters to be added before reducing the below the level required by color print stock.</p>
<p>The L298N motor controller module provides a stable 5 volt DC signal that is used for powering the ESP32 and is wired via a transistor to power the lamp. In theory, the signal provided by the ESP32 to the transistor could be modulated with a PWM channel. The reason this is being avoided at this stage is that PWM, as in it’s name, pulses light to achieve perceptual brightness. In the case of a continuous contact print, this would mean the light would be, essentially, flashing on and off as the film passed by the gate. Using a standard Arduino PWM rate of 5 kHz and assuming the printer is running at an ideal 24 fps (24 Hz) means that the LEDs would blink on and off ~208 per frame. What this <em>could</em> result in is 208 distinct lines along the vertical axis of the image. It’s not a presumption in this project that a PWM-modulated lamp is impossible to make with high-enough of a duty rate or with a properly-designed gate, only that it is a more complicated goal for future work.</p>
<p>The L298N motor controller module provides a stable 5 volt DC signal that is used for powering the ESP32 and is wired via a transistor to power the lamp. In theory, the signal provided by the ESP32 to the transistor could be modulated with a PWM channel. The reason this is being avoided at this stage is that PWM, as in it’s name, pulses light for a specified width (or length of time) to achieve perceptual brightness. Put more simply, PWM is a way to control <em>perceived</em> brightness by turning the LED on and off very quickly.</p>
<p>In the case of a continuous contact print, this would mean the light would be, essentially, flashing on and off as the film passed by the gate. Using a standard Arduino PWM rate of 5 kHz and assuming the printer is running at an ideal 24 fps (24 Hz) means that the LEDs would blink on and off ~208 per frame. What this <em>could</em> result in is 208 distinct lines along the vertical axis of the image. It’s not a presumption in this project that a PWM-modulated lamp is impossible to make with high-enough of a duty rate or with a properly-designed gate, only that it is a more complicated goal for future work.</p>
<h2 id="the-gate">The Gate</h2>
<figure>
<img src="../img/contact_printer_gates.svg" style="width:5.5in;height:1.92in" alt="" /><figcaption>Illustration of all four available gates</figcaption>
@ -87,11 +88,11 @@
</figure>
<p>Being able to control what selected area along the horizontal axis of the image gets exposed is important when printing with soundtracks. For a print to be made with sound the gate must allow for a clean separation between the picture area and the soundtrack area of the film. Sound bleeding into the picture area can affect one side of the image and image bleeding into the soundtrack area can cause a 24Hz hum or other distortion to the audio. For this reason the standard picture gate and the soundtrack gate should be able to allow light from the lamp to pass onto areas of the film stock that they isolate from one another.</p>
<figure>
<img src="" alt="" /><figcaption>Illustration of the picture and soundtrack gates side by side</figcaption>
<img src="../img/contact_printer_picture_sound.svg" style="width:4in;height:2.42in" alt="" /><figcaption>Illustration of the picture and soundtrack gates side by side</figcaption>
</figure>
<p>An example process for making a print with an image and a soundtrack negative would be to run the unexposed, undeveloped print stock with the negative film containing the negative while using a picture gate and then rewinding the print stock and running it again with the soundtrack negative and the soundtrack gate. This would first expose the picture onto the print stock and then, without developing, add the soundtrack to <em>only</em> the soundtrack area of the print. Then it could be developed and projected. It is a relatively simple process but it requires precision in the gates to ensure that the areas the two gates expose are complimentary and not interfering to one another.</p>
<h2 id="the-frame">The Frame</h2>
<p>Within reason, the aluminum frame for this project is resizable. The first draft of the original prototype was made to support 100 foot daylight spools and was 300 mm by 175 mm (11.8" x 6.9“). This was changed increase the dimensions to allow for 400 foot reels and is now 400 mm by 260 mm (15.75” x 10.25"). Being able to reduce or increase the area of the frame is one way to make it easier to modify and customize tools built using this platform. There is nothing preventing the creation of a version of this printer with a much larger footage capacity by expanding the frame even further.</p>
<p>Within reason, the aluminum frame for this project is resizable. The first draft of the original prototype was made to support 100 foot daylight spools and was 300mm by 175mm (11.8" x 6.9“). This was changed increase the dimensions to allow for 400 foot reels and is now 400mm by 260mm (15.75” x 10.25"). Being able to reduce or increase the area of the frame is one way to make it easier to modify and customize tools built using this platform. There is nothing preventing the creation of a version of this printer with a much larger footage capacity by expanding the frame even further.</p>
<p>Aluminum extrusion as a choice for building DIY machines has proven to be effective for desktop 3D printers and CNC machines. There is general availability of common gauges and profiles and aluminum can be cut by hand or with typical shop equipment. For these prototypes, lengths of aluminum 2020 T-slot profile extrusion were cut either by hand using a hacksaw or by drop saw. As a framing material it is light, sturdy and holds up to substantial forces when secured with panels and other brackets.</p>
<figure>
<img src="../img/contact_printer_frame.svg" style="width:5.5in;height:2.5in" alt="" /><figcaption>Illustration of the 2020 aluminum extrusion frame with lengths separated</figcaption>
@ -99,17 +100,24 @@
<p>It would be possible to increase the rigidity, if needed, by adding additional intermediary crossing lengths but for this prototype a total of six (6) lengths connected by five (5) panels and eight (8) corner brackets has been sturdy enough for all tests.</p>
<h2 id="the-firmware">The Firmware</h2>
<p>The Arduino platform uses a subset of C++ which has the benefits of being approachable and easy to use while at the same time preserving the functionalities of the full C++ language for when they are needed. The project is built with an object-oriented programming style that allows for abstraction over the functionality of the physical hardware and other features at the class level. This approach serves the project’s larger goal to leverage modularity by making use of pre-existing classes and creating reusable ones for other projects.</p>
<p>The firmware can be compiled and uploaded using the Arduino IDE<span class="citation" data-cites="arduino-ide"><sup>17</sup></span> or the arduino-cli<span class="citation" data-cites="arduino-cli"><sup>18</sup></span> application using the “esp32:esp32:esp32” FBQN (Fully Qualified Board Name). The code can be compiled <em>without</em> the ESP32 Arduino libraries and just the standard AVR libraries but the GPIO usage and LED PWM channel usage is such that it would have to be refactored to work on another board. Had this project targeted a different Arduino board from the start there would be limitations in the PWM duty rates of the motors and the ability to add network features.</p>
<p>The firmware can be compiled and uploaded using the Arduino IDE<span class="citation" data-cites="arduino-ide"><sup>18</sup></span> or the arduino-cli<span class="citation" data-cites="arduino-cli"><sup>19</sup></span> application using the “esp32:esp32:esp32” FBQN (Fully Qualified Board Name). The code can be compiled <em>without</em> the ESP32 Arduino libraries and just the standard AVR libraries but the GPIO usage and LED PWM channel usage is such that it would have to be refactored to work on another board. Had this project targeted a different Arduino board from the start there would be limitations in the PWM duty rates of the motors and the ability to add network features.</p>
<p>Functionality is abstracted into three classes: the high-level “ContactPrinter” class which then imports the “DriveMotor” and “Lamp” classes. There is a stub for the HTTP networking features named “WebGUI” which does not do anything but host a placeholder page at this time. The ContactPrinter class manages the take-up motors directly but the DriveMotor class is broken out into its own abstraction because it is expected to stabilize and manage the speed of the drive motor more accurately with feedback from the drive motors encoder and also keeps track of the number of frames passed using the same encoder data. The Lamp class, at this time, simply turns the contact printer lamp on or off using a method.</p>
<p>The initial release of the firmware simply starts the printer when a button is pressed, turns the lamp on after 24 frames pass and stops it when that same button is pressed. Additional features, to be discussed in future work, can allow for the adjustment of several behaviors; changing the number of frames that pass before the lamp is struck, running only for a set number of frames, reducing the speed of the printer, etc.</p>
<h1 id="future-work">Future Work</h1>
<h2 id="interfaces">Interfaces</h2>
<p>Physical interfaces are another area of future expansion and development. Requests have been made, for example, to add a dial for controlling lamp brightness. This was avoided in the prototyping phase because it would add parts to the bill of materials and create additional potential points of failure in the wiring.</p>
<p>A simple but robust web interface could be added to control variables for each print: drive motor speed, number of frames to print before stopping, number of frames to run before striking lamp and others. It could also easily show statistics on each print such as actual speed, variation over a run and other information which would highlight any particular issues. With the ESP32 platform the printer could be set up as a standalone Wifi access point (like a router) so that devices can connect to it like clients and allow the web app to be accessed from the connected device. It could also be set up as a Wifi client and exist on a local network and be connected to by any other device on the network with access to it.</p>
<p>Bluetooth is another option as the ESP32 board has dual radios for both Wifi and BLE. This could control the same variables as a web app could but be connected to by a native mobile application or a web app on a browser that supports the Web Bluetooth API.<span class="citation" data-cites="web-bt-api"><sup>20</sup></span> There is no reason that both web and BLE features cannot be developed in parallel to have matching APIs to allow the greatest number of clients to connect, the only consideration that should be made is that these features not impact performance-heavy actions such as printing. Introducing delay into, for example, the PID calculations could cause speed fluctuations that would result in uneven exposures on prints.</p>
<h2 id="sound">Sound</h2>
<p>Creating a sound camera from this platform is</p>
<p>The traditional process of making a soundtrack negative for contact printing requires a separate strip of film and often an expensive service that is not available everywhere. Creating a sound camera from this platform is a secondary goal that has been factored into the design from the early stages. In practice, this would require creating a alternate lamp or entire panel that would replace the lamp and gate with new module consisting of a exciter lens from an Eiki or B&amp;H projector and an “opt-snd”<span class="citation" data-cites="spudic-device"><sup>21</sup></span> digital sound camera. Being able to print image and stripe a soundtrack onto the same piece of print stock using a digital audio file would reduce, tremendously, the steps and materials needed to make sound prints.</p>
<p>While discussing this with others, it was suggested that a fly wheel mechanism, like a projector uses, may be needed at the point the sound is written to film. This may, or may not, be required because the purpose of the fly wheel in a projector is to dampen the intermittent motion of the projector on the film strip as it passes by the exciter lamp and sound reader. This design is <em>not</em> an intermittent motion printer and if the speed of the drive motor is constant enough then the sound should be written without much distortion.</p>
<h2 id="color-lamp-control">Color Lamp Control</h2>
<p>A digitally-controlled color-changing lamp is an appealing and plausible goal. RGB LEDs are everywhere and easy to program. Consider first that PWM is the most common method used to control affordable RGB LEDs. The aforementioned concerns about PWM duty rate must be addressed for this feature to take shape. Consider that as a typical RGB LED package that is controlled via PWM by flickering the red, green and blue LEDs at different pulse widths to change the perceptual color. Sometimes a low-level controller chip will change the individual color channel rates, as well. This means that, similar to the issue with “white” LEDs creating lines on a print, in a color printing scenario there could be horizontal lines of different colors that are noticeable across the frame.</p>
<p>The ability to track per-frame position also makes features like this attractive. An idealized system could enable films to be printed with each frame a different lamp value. This is an incredible idea but requires control and accuracy that are very difficult to achieve with a DIY project. It is within the realm of possibility but it is firmly in the world of future work for the reason that it goes beyond the standard use case for a desktop contact printer which is to make a work or release print from a single roll of negative film.</p>
<h2 id="multi-format">Multi-format</h2>
<p>The Kinograph DIY scanner project<span class="citation" data-cites="kinograph"><sup>19</sup></span> presents an example of a 3D-printed multi-format sprocketed roller capable of transporting 16mm, 8mm and 35mm gauge film material. This is a possibility to consider, though it would introduce new design challenges. First would be the need to create new lamps and gates for each format. Next would be the question of speed and the resulting exposure. Could the drive motor be slowed or sped up to allow for these formats to print properly? There is also the question of need: is it necessary to create an 8mm gauge printer at all?</p>
<p>There is nothing, in principle, in this contact printer platform design that would prevent it from being adapted for other movie film formats and there is precedent. The Kinograph DIY scanner project<span class="citation" data-cites="kinograph"><sup>22</sup></span> presents an example of a 3D-printed multi-format sprocketed roller capable of transporting 16mm, 8mm and 35mm gauge film material. This is a possibility to consider, though it would introduce new design challenges.</p>
<p>First would be the need to create new lamps and gates for each format. The take-ups would have to have their spindles extended to support 35mm cores and the idle rollers would have to be enlarged for the same Next would be the question of speed and the resulting exposure. Could the drive motor be slowed or sped up to allow for these formats to print properly?</p>
<p>There is also the question of need: is it necessary to create an 8mm gauge printer at all? 8mm gauge print stock is rare if non-existent though there is, in theory, the capability to slit and re-perforate the stock as is done for the Double 8 and Super 8 formats.</p>
<h3 id="research-supporters">Research Supporters</h3>
<p><img src="../img/EN_FundedbytheEU_RGB_POS.png" style="width:5.5in;height:1.2in" /></p>
<h3 class="unnumbered" id="references">References</h3>
@ -147,28 +155,37 @@
<div id="ref-ender3">
<p>11. <a href="https://www.creality.com/products/ender-3-3d-printer">https://www.creality.com/products/ender-3-3d-printer</a>.</p>
</div>
<div id="ref-perforations">
<p>12. Film perforations. <a href="https://en.wikipedia.org/wiki/Film_perforations">https://en.wikipedia.org/wiki/Film_perforations</a>.</p>
</div>
<div id="ref-param-roller">
<p>12. <a href="https://git.sixteenmillimeter.com/modules/sprocketed_roller">https://git.sixteenmillimeter.com/modules/sprocketed_roller</a>.</p>
<p>13. <a href="https://git.sixteenmillimeter.com/modules/sprocketed_roller">https://git.sixteenmillimeter.com/modules/sprocketed_roller</a>.</p>
</div>
<div id="ref-mcopy">
<p>13. Mcopy - an open platform for controlling small-gauge film optical printers. <a href="https://sixteenmillimeter.com/projects/mcopy/">https://sixteenmillimeter.com/projects/mcopy/</a>.</p>
<p>14. Mcopy - an open platform for controlling small-gauge film optical printers. <a href="https://sixteenmillimeter.com/projects/mcopy/">https://sixteenmillimeter.com/projects/mcopy/</a>.</p>
</div>
<div id="ref-slp">
<p>14. Shaffer, C. The shaffer linear processor. <a href="https://clydeshaffer.com/slp/">https://clydeshaffer.com/slp/</a>.</p>
<p>15. Shaffer, C. The shaffer linear processor. <a href="https://clydeshaffer.com/slp/">https://clydeshaffer.com/slp/</a>.</p>
</div>
<div id="ref-slp-clutch">
<p>15. Shaffer, C. Bulding the slp. <a href="https://clydeshaffer.com/slp/posts/01_how2build.php">https://clydeshaffer.com/slp/posts/01_how2build.php</a>.</p>
<p>16. Shaffer, C. Bulding the slp. <a href="https://clydeshaffer.com/slp/posts/01_how2build.php">https://clydeshaffer.com/slp/posts/01_how2build.php</a>.</p>
</div>
<div id="ref-takeup">
<p>16. Modules/takeup: Modular takeup design for winding film using a magnetic coupling. <a href="https://git.sixteenmillimeter.com/modules/takeup">https://git.sixteenmillimeter.com/modules/takeup</a>.</p>
<p>17. Modules/takeup: Modular takeup design for winding film using a magnetic coupling. <a href="https://git.sixteenmillimeter.com/modules/takeup">https://git.sixteenmillimeter.com/modules/takeup</a>.</p>
</div>
<div id="ref-arduino-ide">
<p>17. Software | arduino. <a href="https://www.arduino.cc/en/software/">https://www.arduino.cc/en/software/</a>.</p>
<p>18. Software | arduino. <a href="https://www.arduino.cc/en/software/">https://www.arduino.cc/en/software/</a>.</p>
</div>
<div id="ref-arduino-cli">
<p>18. GitHub - arduino/arduino-cli: Arduino command line tool. <a href="https://github.com/arduino/arduino-cli">https://github.com/arduino/arduino-cli</a>.</p>
<p>19. GitHub - arduino/arduino-cli: Arduino command line tool. <a href="https://github.com/arduino/arduino-cli">https://github.com/arduino/arduino-cli</a>.</p>
</div>
<div id="ref-web-bt-api">
<p>20. Web bluetooth api - web apis | mdn. <a href="https://developer.mozilla.org/en-US/docs/Web/API/Web_Bluetooth_API">https://developer.mozilla.org/en-US/docs/Web/API/Web_Bluetooth_API</a>.</p>
</div>
<div id="ref-spudic-device">
<p>21. Spudić, H. DIY 16mm optical sound recorder, v2: The device. <a href="https://hrvojespudic.net/optical-sound-2-pt-2">https://hrvojespudic.net/optical-sound-2-pt-2</a>.</p>
</div>
<div id="ref-kinograph">
<p>19. Kinograph. Kinograph - about. <a href="https://www.kinograph.cc/about">https://www.kinograph.cc/about</a>.</p>
<p>22. Kinograph. Kinograph - about. <a href="https://www.kinograph.cc/about">https://www.kinograph.cc/about</a>.</p>
</div>
</div>

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docs/whitepaper/contact_printer_whitepaper.pdf
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12
docs/whitepaper/sources.bib
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@ -160,4 +160,16 @@
title={GitHub - arduino/arduino-cli: Arduino command line tool},
url={https://github.com/arduino/arduino-cli},
urldate={2025-04-15}
}
@online{web-bt-api,
title={Web Bluetooth API - Web APIs | MDN},
url={https://developer.mozilla.org/en-US/docs/Web/API/Web_Bluetooth_API},
urldate={2025-04-25}
}
@online{perforations,
title={Film perforations - Wikipedia},
url={https://en.wikipedia.org/wiki/Film_perforations},
urldate={2025-04-25}
}

10
scad/illustrations.scad
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@ -1,3 +1,4 @@
use <./sprocketed_roller/scad/sprocketed_roller.scad>;
use <./contact_printer.scad>;
FrameX = 400;
@ -71,7 +72,7 @@ module corner_foot_bolts (pos = [0, 0, 0], rot = [0, 0, 0]) {
}
}
PART = "frame";
PART = "picture_sound";
if (PART == "sprocketed_roller_invert_solid") {
$fn = 200;
@ -132,6 +133,13 @@ if (PART == "sprocketed_roller_invert_solid") {
corner_foot_bolts([-(PanelX / 2) + 10, (FrameY / 2) + 10, FootZ], [0, 0, -90]);
corner_foot_bolts([(PanelX / 2) - 10, -(FrameY / 2) - 10, FootZ], [0, 0, 90]);
corner_foot_bolts([-(PanelX / 2) + 10, -(FrameY / 2) - 10, FootZ], [0, 0, 0]);
} else if (PART == "roller_comparison") {
$fn = 200;
translate([-30, 0, 0]) sprocketed_roller(sprockets = 18);
translate([20, 0, 0]) sprocketed_roller();
} else if (PART == "picture_sound") {
picture_gate_standard([-10, 0, 0]);
picture_gate_sound([10, 0, 0]);
}
/*
PART = "feed_panel_picture";