3D Printed Animatronic Speaking Tiki Statues

My title is Jim Leemhuis. I’m 34 years previous from Lexington, Kentucky. By day, I’m a mechanical engineer serving to design laser printers for Lexmark Worldwide Inc. By evening, I spend my time 3D printing, coding, and assembling animatronic figures.

I’ve spent the final ten years utilizing 3D printing to go with my design work at Lexmark. We use giant SLA resin and Objet printers to create and take a look at printer components and fixtures earlier than releasing merchandise to market. Having the ability to create and take a look at components rapidly was essential for me at work and, in 2015, I bought my Lulzbot Mini so I may create components at house. I discovered I may flip round designs for work in a single day and guarantee they labored earlier than utilizing the bigger (and extra pricey to run) SLA/Objet printers at work to print the ultimate working.

I’ve at all times had a fascination with Disney audio animatronics from a really younger age. It appears, as we speak, like many theme parks are shifting an increasing number of in direction of digital projections, however for my part, nothing beats a bodily determine shifting, speaking, and interacting in entrance of you. I knew after I was older that I’d attempt to construct my very own animatronics. 3D printing, together with open supply platforms like Arduino, has allowed me to do this.

My first main animatronic venture was an audio animatronic bust with a Haunted Mansion theme. This was an enormous leap into open supply electronics and an incredible start line to make sure I may design and print practical components. You possibly can see a video of the ultimate venture right here: https://youtu.be/g5WGrtmRxQU

As soon as I had efficiently accomplished my Haunted Mansion audio animatronic, I knew I wished to do a venture primarily based on the primary present to make use of audio animatronics, Walt Disney’s Enchanted Tiki Room. Everybody I do know loves the chanting tiki totems within the present. After finding out them for a bit, I noticed the animatronics wouldn’t be as advanced as my final venture, however it will undoubtedly be problem to check my 3D design and printing abilities. I had seen individuals who had designed and printed tiki poles earlier than; however nobody I knew had taken on the problem of recreating an enchanted speaking tiki totem that included movement, audio, and synchronized lighting. It’s could be my very own small tribute to these unique Disney Animatronics.

The totem design makes use of a majority of Matterhackers PRO PETG, with PLA and a few ABS used as properly, in smaller quantities. The totem pole construction, prime, and base are all made out of PETG. Why was PETG the correct materials for this job?  PETG has an incredible mixture of robust layer adhesion, minimal warp whereas printing giant components, greater glass transition temperature, together with being rather more sturdy and far simpler to post-process in comparison with PLA. This allowed for very giant components to be printed with out worrying about layer splits (extra widespread in giant ABS prints), breaking printed items as a consequence of brittleness, and being able to have components flex to create tight matches.

Examine this hyperlink to see the Tiki undergo its “present” (Observe: on the time of publication, paint has not been absolutely utilized but): https://youtu.be/DhtXnlpF3e0

After utilizing PETG for this venture, there are a number of ideas I’ve discovered via experimentation with the fabric in addition to from others.

Epoxies and different glues will NOT bond to PETG. You must use a particular solvent used for acrylics. I used SciGrip Weldon #4. Observe that this solvent has the consistency of water and must be utilized with an applicator with a skinny needle. It’s best to have good air flow when making use of this solvent. Making use of outside is finest. Nevertheless, it dries inside a couple of minutes.

I used to be in a position to bond PETG components collectively simply in addition to bonding PETG components to PLA components (though the bond isn’t fairly as robust as PETG to PETG) utilizing Weldon #4. Thanks, @keebie81, for telling me about this nice solvent!

In my expertise, PETG will be very delicate to over extrusion. Remember to set your slicer’s circulation % as little as potential that also offer you a stable first layer. That is very true of components with giant preliminary floor areas. After getting it dialed in, nevertheless, it prints with none concern. This additionally minimized the possibilities of PETG materials sticking to the nozzle throughout printing. PETG appears to wish to keep on with the nozzle more-so than ABS or PLA. When you’re experiencing this concern, attempt decreasing your circulation charge a bit and ensure the Z peak is right.

PETG and ABS have very related sanding properties. By means of testing, I’d rank ABS best to sand with PETG in a really shut second and PLA in a distant third. When you’re trying to submit course of your prints, hold this in thoughts if making an attempt to determine between PETG and PLA as a consequence of their related anti-warping properties. Sanding these pesky layer strains out of PETG shall be a lot faster than PLA.

Whereas warping throughout printing with PETG is minimal, you should still expertise a small quantity on bigger prints. This will trigger a niche between prints in the event you’re adhering two components of an meeting collectively. To fill gaps or seams, utilizing ProBond Wooden Filler works amazingly properly. It’s simple to use along with your finger, cleans up properly with water, dries rapidly, and sands flush to the half extraordinarily simply. I used this to fill in all my seams on my Tiki totem meeting.

Due to @UncleJessy4Real for initially declaring this nice filler product to me.

PETG paints properly when first coated with a sprig can primer. The Speaking Tiki is coated with Rust-oleum Common Bonding Primer. I used to be then in a position to paint the components utilizing normal acrylic paints and a protecting clear enamel coat to guard the paint. 

Total, I’m very happy with how PETG labored for my venture. Whereas it does have its personal challenges, resembling gluing; the minimal printing warp, ease of sanding, elevated half energy, greater glass transition temperature, and half flexibility greater than outweigh the challenges.

My last piece of general recommendation: Pursue a venture you’re extraordinarily enthusiastic about. You usually tend to push your self, study from errors and take a look at once more, and put within the required effort and time when you’re really “addicted” to your venture. Discover that venture that matches what you’re enthusiastic about and don’t stop till you obtain your purpose!

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 Observe together with Speaking Tiki progress by following Jim on twitter @jimscuba2386 or following the venture on Twitter by trying to find #talkingtiki.

Do you have got cool venture the place you employ a particular MatterHackers filament? Tell us within the feedback beneath or ship an e mail to help@matterhackers.com.