3D Printed Animatronic Speaking Tiki Statues

My identify 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 massive SLA resin and Objet printers to create and take a look at printer components and fixtures earlier than releasing merchandise to market. With the ability to create and take a look at components shortly was essential for me at work and, in 2015, I bought my Lulzbot Mini so I may create components at residence. 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, at this time, like many theme parks are transferring an increasing number of in the direction of digital projections, however for my part, 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 venture was an audio animatronic bust with a Haunted Mansion theme. This was an enormous leap into open supply electronics and a fantastic place to begin to make sure I may design and print purposeful components. You may 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 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 learning them for a bit, I spotted the animatronics wouldn’t be as complicated as my final venture, however it could undoubtedly 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 can be my very own small tribute to these authentic Disney Animatronics.

The totem design makes use of a majority of Matterhackers PRO PETG, with PLA and a few ABS used as effectively, 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 a fantastic mixture of robust layer adhesion, minimal warp whereas printing massive components, increased glass transition temperature, together with being rather 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 widespread in massive ABS prints), breaking printed items on account of brittleness, and being able to have components flex to create tight suits.

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

After utilizing PETG for this venture, there are a couple of suggestions I’ve discovered by way of experimentation with the fabric in addition to from others.

Epoxies and different glues will NOT bond to PETG. You want to 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 open air is finest. Nonetheless, it dries inside a couple of minutes.

I used to be capable of 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 may be very delicate to over extrusion. Make sure you set your slicer’s move % as little as doable that also offer you a strong first layer. That is very true of components with massive preliminary floor areas. After you have it dialed in, nevertheless, it prints with none subject. This additionally minimized the possibilities of PETG materials sticking to the nozzle throughout printing. PETG appears to need to persist with the nozzle more-so than ABS or PLA. In case you’re experiencing this subject, attempt lowering your move charge a bit and ensure the Z peak is right.

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. In case you’re seeking to submit course of your prints, hold this in thoughts if attempting to determine between PETG and PLA on account of their comparable anti-warping properties. Sanding these pesky layer strains out of PETG can 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 niche between prints for those who’re adhering two components of an meeting collectively. To fill gaps or seams, utilizing ProBond Wooden Filler works amazingly effectively. It’s straightforward to use along with your finger, cleans up properly with water, dries shortly, 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 effectively when first coated with a sprig can primer. The Speaking Tiki is coated with Rust-oleum Common Bonding Primer. I used to be then capable of paint the components utilizing commonplace acrylic paints and a protecting clear enamel coat to guard the paint. 

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

My closing piece of general recommendation: Pursue a venture you’re extraordinarily keen about. You usually tend to push your self, be taught from errors and check out once more, and put within the required effort and time when you find yourself really “addicted” to your venture. Discover that venture that matches what you’re keen 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’ve got cool venture the place you employ a particular MatterHackers filament? Tell us within the feedback under or ship an electronic mail to assist@matterhackers.com.