Maltese Falcon - Full Size

prusaprinters

<p>Detective Tom Polhaus: "Heavy. What is it?"<br/> Sam Spade: "The, uh, stuff that dreams are made of."</p> <p>Update Jan.21, 2012 : Added the full size STEP file (unmodified - one piece) for anyone who want to play around with it.</p> <p>The Maltese Falcon is a great movie - you should watch it. Seriously - go watch it NOW!</p> <p>My printer does not have the build volume to be able to print this full size in one piece, so I sliced it into four pieces in CAD, partially hollowed out each piece to reduce filament usage, and added dowel pin holes in all pieces to help align them for re-assembly.</p> <p>The four pieces (from the head down) are as follows :</p> <pre><code> Filament Cost Print </code></pre> <p>Part Used (g) US$ Time<br/> ====== ======== ====== =======<br/> Head 115 $2.92 9h39m<br/> Chest 129 $3.28 9h08m<br/> Feet 130 $3.32 13h27m</p> <h3>Base 113 $2.60 7h46m</h3> <p>Totals 487 $12.12 40h0m</p> <p>In addition to the four falcon sections, I also included a print for dowel pins (or you can use 1/4" (6mm) wood dowels). The "hollows" in each section interconnect in the assembled piece; I plan to fill the inside with cement to give the model some heft.</p> <p>Attribution : I found this STL by Colin Freeman:</p> <p><a href="https://www.thingiverse.com/thing:46631">https://www.thingiverse.com/thing:46631</a></p> <p>I used FreeCAD to convert the STL to a solid, then imported it into OnShape and scaled it up to 12" in height.</p> <p>The OnShape 3D CAD files for this are here :</p> <p><a href="https://cad.onshape.com/documents/5dc5d43e08a62b25512b4675/w/4b8a46f5290a08139e3ec483/e/3ecdd6c687b8a217dbc24955">https://cad.onshape.com/documents/5dc5d43e08a62b25512b4675/w/4b8a46f5290a08139e3ec483/e/3ecdd6c687b8a217dbc24955</a></p> <h3>Print instructions</h3><p>Print in PLA using the 3mf files provided; otherwise :</p> <ul> <li>perimeters = 3</li> <li>10% - 15% rectilinear infill</li> <li>detachable supports</li> </ul> <p>Supports required for the sections are as follows :</p> <ul> <li>head : under the beak</li> <li>chest : none required</li> <li>feet : under the front claws, and two small areas on the sides</li> <li>base : print upside down, no supports</li> </ul> <p>For the dowel halves, I increased elephant's foot compensation to 0.4mm. I have also included a test block for testing the dowel fit - the dowels should fit firmly but not so tight that it is difficult to insert or remove them. It is not necessary to glue the dowel halves together - simply hold the two halves together while inserting.</p> <p>Six dowels are needed to align the pieces for assembly. I printed the dowels in halves - this enables better bed adhesion and allows the dowels to be printed linearly for greater strength. The provided gcode will print all 12 required halves individually in one session.</p>