Vote Now – Formlabs 3D Design Awards

2017 Formlabs 3D Design Awards

This morning I’ve woken to some exciting news – 3 of my products, which have been featured right here on my blog, have been announced as finalists in 3 separate categories of this years Formlabs 3D Design Awards!!

If you’ve enjoyed following my 3D printing projects, I would love it if you could take 30 seconds to follow this link to the voting page, click on the big green START button, and select my 3 designs. Winners are determined by quantity of votes from the public, so get voting now! The 3 products are:

  1. Art and Design Category: X-Men Cyclops Goggles (pictured above)
  2. Engineering Category: Garmin Virb X Floaty Mount
  3. Education Category: Pine 64 Snap Enclosure

Make sure you take some time to check out the other designs as well – there is some stiff competition in each category, and some great models to download and 3D print.

Thanks in advance for your support 🙂

– Posted by James Novak

X-Men Cyclops Goggles – COMPLETE

20150717 Cyclops Goggles

As featured on Pinshape’s ‘Pick of the Week

After what seems like months, finally I’ve found time to photograph and share my X-Men Cyclops goggles, which I created for a costume party. You can catch up with the journey in my last post 3D printing them, or the first one designing them by clicking the links. You can also download these exclusively from Pinshape – just click here!

For the first time, because of the work involved in creating these, and the fact I just think they’re really cool, I’ve put a small price on these at $4.97 to download. To date I’ve given all my models away for free, but at some point it’s important to give value to a design. I’m not interested in making money on these, just to add a sense of value for the time and effort involved in creating something like this, which is designed to print on a small desktop 3D printer like my Up! Plus 2 in 4 pieces. I have designed in special locators to make assembling and gluing very easy, and also nice and strong.

20150718 Cyclops Novak

If you have a close look at the design you will probably notice a few interesting things:

  1. The smooth surface finish. This was achieved by spraying multiple coats of a putty undercoat and sanding back to remove the ‘layered’ effect. A final colour was then sprayed on top, with the black details painted by hand. You can see how the layers stood out when the first undercoat was applied in the image below – often these are much less noticeable in the white ABS plastic!
  2. The red visor is not 3D printed – it was cut from a folder and is translucent enough to see out of.
  3. LED’s – yes everything’s better with LED’s! While only glued on roughly, at night, and at the party, they looked pretty awesome (although I felt pretty weird after seeing nothing but red while wearing them!).
  4. Foam was glued into the ear pieces to create a firm fit. As mentioned in my first post designing these, I used a previous 3D scan of my face to get the dimensions right – however knowing that I wanted to share them on a site like Pinshape, I kept the design simple in its details so that it could fit anyone. Obviously we all have differently-shaped heads, so it’s never going to be perfect for everyone, so tweaking the print with something like foam might be necessary. You might also need to scale the print depending on your head size – the critical dimensions are on Pinshape.

2015-07-07 16.15.48 smallOverall this is a really fun design that I hope a few people get some enjoyment from making. Cyclops isn’t the most exciting character in recent movies, but as a kid, I loved watching the cartoon version where he wore these style of goggles. Bring back that version of Cyclops I say! If you make these and wear them to a convention or party, please post images on Pinshape so I can check them out!

– Posted by James Novak

Cyclops – Step 2

2015-07-01 Cyclops “Don’t anybody move!… I lost my contact lens.”

OK so here it is, I’ve finished 3D printing the 4 pieces of my X-Men Cyclops goggles (read about my initial design of them here) and glued them together with superglue. Pretty cool if I do say so myself! You can see the settings I used on my Up! Plus 2 printer below – I kept things nice and slow to minimise print errors (an ongoing problem with my printer that can result in the print shifting or skipping – see my previous post on this issue). As a result, the ear pieces took 5 hours each, and the lens pieces 4.5 hours each, resulting in a total print time of 19 hours. Of course this could be cut down quite a lot depending on the settings of your own printer and the layer thickness you end up using.

150702 CyclopsNow that the glue is drying my next steps will be to prime and sand the goggles ready to spray paint. I don’t know yet how much effort I’m going to put into smoothing the visible layers, I’ll work it out once I start getting my hands dirty and see what they look like. Perhaps a bit of acetone prior to painting will work (see my previous results with acetone) or just a few steps of spraying undercoat and sanding. The pieces have aligned very well using the locating notches I designed into them, just some very minor differences in surfaces where the lenses come together in the middle. Should be relatively easy to clean up with some sanding.

Overall the fit is pretty close, once the glue dries completely I’ll get a better idea of whether a little bit of padding might be needed either in the nose area or around the ears to keep them securely in place. I also need to still figure out how I’m going to add the lens and some sort of lighting effect – if you’re going to make something, you may as well go all out!

– Posted by James Novak

Cyclops – Step 1

150623 Cyclops

With a costume party fast approaching I couldn’t turn up without at least some part of my outfit 3D printed could I? Originally I had planned to go as Thomas from Daft Punk after finding the helmet files on Thingiverse, however this is a seriously involved 3D print with around 30 pieces to print, glue, smooth, paint and install electronics! As much as this would be an awesome project, I can’t really justify that amount of time, and probably wouldn’t finish it in time anyway. Searching for something smaller, Cyclops from X-Men became my next option – I’ve never been a fan of the movie version played by James Marsden, but growing up watching the cartoon version he was always my favourite. The best image I could find of the goggles is on the left.

A quick look on Thingiverse didn’t bring up anything that really looked any good, so today’s job has been to model the trademark goggles worn by Cyclops (not the lame looking sunglasses!). I’ve previously had a 3D scan of my face done, and used it to build a perfect-fitting Virtual Reality headset – this seemed like a great starting point to get the dimensions correct. Originally I was going to make these goggles fit perfectly as well, using the surfaces of the 3D scan to shape them. However I’d like to share this design on Thingiverse, and doubt there are too many clones of me out there who would fit it! So I’ve just used the scan to get the sizing correct for my face, and kept the geometry much more generic so that it should suit most people, perhaps with some scaling to shrink/enlarge it for different head shapes. You can see how I’ve modeled half of the design in Solidworks in the right image, with the biggest challenge being to get the eye-slot in the right spot and the rest of the geometry proportional around this. The slot is quite narrow so it needs to be correct or I won’t be seeing very much!

150624 Cyclops

I have sliced the model up into 4 sections so that it can be printed on the small print plate of my Up! Plus 2 3D printer – notice the small slots I’ve added to allow for easy alignment and gluing. Now just to print, glue, paint, and figure out how to achieve the red eye-piece and light it up. Once that’s all done and I know it works (fingers crossed!) I’ll upload it to Thingiverse 🙂

– Posted by James Novak