While on a recent family vacation (all 26 of us), the wife and I took the family members to a variety of attractions, one of which was a museum with a fascinating automata. The kids and grandkids suggested I design and 3D print a version of the automata using Darth Vader as opposed to the generic figure of the museum piece, and "Darth" is the result.
While much smaller than, and much less complex as, the museum piece, Darth is still quite a challenge to print, assemble and align. The design incorporates 26 unique 3D printed parts (81 total 3D printed parts) and utilizes eight 3D printed turnbuckles, having both left and right hand threads, for fine tuning. The process of how I printed, assembled and aligned the various Darth components is described below.
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 point them out as I do make mistakes in plenty.
Designed using Autodesk Fusion 360, sliced using Cura 3.5.1, and printed in PLA on an Ultimaker 2+ Extended and an Ultimaker 3 Extended.
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