Darth 2: a 3D Printed Animated <PERSON> Helmet.
Introduction: Darth 2: a 3D Printed Animated <PERSON> Helmet.
I designed and 3D printed "Darth 2: A 3D Printed Animated <PERSON> Helmet", with a twist, for our grandkids who are Star Wars fans!
This animated twisting <PERSON> Helmet is constructed from eighteen helmet slices similar to my "A 3D Printed Animated Valentine Heart for My Valentine!" (https://www.instructables.com/A-3D-Printed-Animated-Valentine-Heart-for-My-Valen/) model. This model animates just the head section from my first <PERSON> design (https://www.instructables.com/Darth/). With extra room in each head slice, I was able to simplify this model by adding 3D printed pins as opposed to the metal pins used in the heart design thus saving the metal pin machining and insertion steps during construction.
As in the heart design, the motor and gear system in this model is designed to rotate the top slice 180 degrees while holding the bottom slice stationary, then hold the top slice stationary while rotating the bottom slice 180 degrees.
And again as in the heart design, to rotate the inner slices (between the top and bottom) the bottom and inner slices contain 3D printed pins and the inner and top slices contain slots. Each pin fits into the slot in the slice above it, and each pin and slot is designed to allow a 10 degree rotation before contacting the pin below. Thus when the top slice turns 10 degrees, its slot comes in contact with the pin in the slice below and that slice begins to rotate, and when the slice below rotates 10 degrees, the pin in the slice below it begins to rotate. This process continues down the slices until the top rotates 180 degrees at which point the bottom begins to rotate to put the helmet back together.
The only contact between each slice must be the pins in the slots, thus careful 3D printing (no warping) and assembly (bearings completely flush with the top and bottom of each slice) are required to successfully 3D print and assemble this model.
As usual I probably forgot a file or two or who knows what else, so if you have any questions, please do not hesitate to comment as I do make plenty of mistakes.
Designed using Autodesk Fusion 360, sliced using Ultimaker Cura 4.8.0, and 3D printed in PLA on Ultimaker S5s.
Supplies
* Soldering iron and solder.
* Light machine oil to lubricate the gears and axles.
* Thick cyanoacrylate glue.
Step 1: Parts.
I acquired the following parts:
* One 2AAA battery back with switch (optional if not using a power supply and jack).
* Two AAA batteries (optional if not using a power supply and jack).
* One 300RPM 6VDC N20 gear motor.
* Sixteen bearings (10 x 15 x 4mm).
* 3VDC power supply with compatible coaxial power jack (optional if not using a battery pack and batteries).
I 3D printed all parts at .1mm layer height with 20% infill. 646
I 3D printed 2 "Bolt, Plate.stl", 15 "Spacer.stl" and one each of the remaining parts.
This mechanism is a high precision print and assembly using at times very small precision 3D printed parts in confined spaces with highly precise alignment. I 3D printed all parts using the Ultimaker Cura 4.8.0 "Engineering Profile" on my Ultimaker S5s, which provides a highly accurate tolerance requiring minimal if any trimming, filing, drilling or sanding. However, prior to assembly, I still test fitted and trimmed, filed, drilled, sanded, etc. all parts as necessary for smooth movement of moving surfaces, and tight fit for non moving surfaces. Depending on your slicer, printer, printer settings and the colors you chose, more or less trimming, filing, drilling and/or sanding may be required to successfully recreate this model. I carefully filed all edges that contacted the build plate to make absolutely certain that all build plate "ooze" is removed and that all edges are smooth using small jewelers files and plenty of patience.
This mechanism also uses threaded assembly, so I used a tap and die set (8mm by 1.25) as required for thread cleaning.
Step 2: Assembling the Darth Vader Helmet Slices.
The bearings and slices are each 4mm thick, and the bearings must be flush with the top and bottom of the slices. 632