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 night time, 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 massive 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 dwelling. 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, right now, like many theme parks are transferring increasingly in the direction of digital projections, however in my view, nothing beats a bodily determine transferring, speaking, and interacting in entrance of you. I knew after I was older that I might attempt to construct my very own animatronics. 3D printing, together with open supply platforms like Arduino, has allowed me to try this.

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

As soon as I had efficiently accomplished my Haunted Mansion audio animatronic, I knew I needed to do a challenge based mostly 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 complicated as my final challenge, however it might positively be problem to check my 3D design and printing expertise. 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 nicely, in smaller quantities. The totem pole construction, high, and base are all made out of PETG. Why was PETG the correct materials for this job?  PETG has an excellent mixture of sturdy layer adhesion, minimal warp whereas printing massive components, greater glass transition temperature, together with being way more sturdy and far simpler to post-process in comparison with PLA. This allowed for very massive components to be printed with out worrying about layer splits (extra frequent in massive ABS prints), breaking printed items attributable to brittleness, and being able to have components flex to create tight suits.

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

After utilizing PETG for this challenge, there are a number of ideas I’ve realized by means of experimentation with the fabric in addition to from others.

Epoxies and different glues will NOT bond to PETG. It’s essential use a particular solvent used for acrylics. I used SciGrip Weldon #4. Notice that this solvent has the consistency of water and must be utilized with an applicator with a skinny needle. You need to have good air flow when making use of this solvent. Making use of outdoor is greatest. Nonetheless, 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 sturdy as PETG to PETG) utilizing Weldon #4. Thanks, @keebie81, for telling me about this nice solvent!

In my expertise, PETG might be very delicate to over extrusion. Make sure you set your slicer’s movement % as little as attainable that also offer you a stable first layer. That is very true of components with massive preliminary floor areas. After getting it dialed in, nevertheless, it prints with none problem. This additionally minimized the possibilities of PETG materials sticking to the nozzle throughout printing. PETG appears to wish to persist with the nozzle more-so than ABS or PLA. If you happen to’re experiencing this problem, strive decreasing your movement fee a bit and ensure the Z top is appropriate.

PETG and ABS have very comparable sanding properties. Via testing, I’d rank ABS best to sand with PETG in a really shut second and PLA in a distant third. If you happen to’re seeking to put up course of your prints, preserve this in thoughts if attempting to determine between PETG and PLA attributable to their comparable anti-warping properties. Sanding these pesky layer traces out of PETG might 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 may occasionally trigger a spot between prints should you’re adhering two components of an meeting collectively. To fill gaps or seams, utilizing ProBond Wooden Filler works amazingly nicely. It’s simple to use together 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 nicely when first coated with a twig 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. 

General, I’m more than happy with how PETG labored for my challenge. Whereas it does have its personal challenges, corresponding to 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 total recommendation: Pursue a challenge you might be extraordinarily keen 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 find yourself actually “addicted” to your challenge. Discover that challenge that matches what you’re keen about and don’t give up till you obtain your purpose!

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

Do you’ve got cool challenge the place you utilize a selected MatterHackers filament? Tell us within the feedback under or ship an e mail to help@matterhackers.com.