3D Printing

3D Printed Parts

Parts are designed to be 3D printed with FDM based machines. STL files are oriented to print "as is". Machines with dual extrusion or single extrusion setups are listed below with parts name and description. Parts require tight tolerances that might need adjusting slice setting. Reference the suggested settings below.

Domes Halves

The geodesic sphere is comprised of two 3D printed domes. The dome can be 3d printed using a multi-material tool head or a single extrusion 3d printer. The dome models can be 3d printed without any support material.

Build Requirement: 182mm (7in) x 82mmm (3in) 

CURA Slicing

The multi-colored dome was slice using Ultimaker's CURA 3.x for an Ultimaker S5 and 3. The model does not require a prime tower or any additional support to print properly. Parts A and B are assigned to extruder 1 and 2 with respects to the preloaded colored filament. The B labeled model is indented for translucent filament.

Printing Times

A tool head with larger diameter nozzle can dramatically speed up the printing time. Here's some time estimates comparisons of printing the dome with a 0.4mm and 0.8mm nozzle (single and dual extruded). Note thicker layer height. Another trick to reduce print time is to set infill to 0%.

Single Extruded Domes

  • 17h 42m – 0.2 layer height 0.4mm nozzle
  • 4h 51m – 0.4 layer height 0.8mm nozzle

Dual Extruded Domes

  • 6h 37m - dual extruded dome - 0.4 layer height / 0.8mm nozzle
  • 21h 38m – 0.2 layer height 0.4mm nozzle

Parts Assemblies

There are several parts in this build. Below are the subassemblies sectioned out with file names of each part. The thumbnail gives a visual of the part.

Base Assembly

Most of the main components are mounted to the stand. The speaker, button and triper featherwing mounting plates are secured the stand using standoff and machine screws. The base box covers the components and snap fits onto the stand.

  • base-plate.stl
  • base-box.stl
  • button-plate.stl
  • tripler-mount.stl

Servo Assembly

Parts for the servo mount. The tabs are used as spacers in between the servo mounting tabs. 

  • servo-mount.stl
  • servo-brace.stl
  • servo-hub.stl
  • servo-tab.stl

Idler Assembly

The spikes are super glued to the grooves on the side of the idler. 

  • idler-adapter.stl
  • idler-cap.stl
  • idler-pulley.stl
  • idler-spike.stl
  • idler-mount.stl

Roller Assembly

This sub assembly will need to be 3d printed twice. Each dome will need a roller assembly so make two sets. 

  • dome-frame.stl
  • pixelcore.stl
  • roller-idler.stl
  • roller-plate.stl
  • roller-wheel.stl

Sphere Assembly

The domes are dual extruded in dark and translucent material. Optionally, 3D print a unified version for a single extruder. 

  • geodesic-A.stl
  • geodesic-B.stl
  • geodesic-dome.stl

Tap Mounting Holes

I used a set of screw taps to create threads in the various mounting holes. This greatly improves fastening screws. of the A mix of metric sizes are used here. M2.5 and M3 taps for the various mounts.

Design Source Files

The enclosure assembly was designed in Fusion 360. This can be downloaded in different formats like STEP, SAT and more. Electronic components like the board, displays, connectors and more can be downloaded from our Fusion 360 CAD parts github repo.

This guide was first published on Dec 29, 2018. It was last updated on Dec 29, 2018. This page (3D Printing) was last updated on Sep 28, 2019.