C-3PO Build

[Conqueror_Worm]

I've been seeing some really nice 3D printed droids in the C-3PO builders Facebook group, and I've decided that I need to get in on this. The models by Jesse_M seem to be the most popular, so thats what I'll be using. My printer is a CR-10, and I used CC3D PLA Silk Gold filament. Model was sliced into 0.2mm layers using Cura.

The assembly:

Some pictures of the printing chaos:

Unfortunately, it doesn't fit my head. I think if I scaled it up about 5% and reprinted it, I could wear it. I think I could get away with making it a little bigger, it looks pretty small next to the other buckets:

Torso V2 model by Jesse (scaled to 105%), Hatchbox PLA, 0.3mm layer height, 35 hours print time.

Left Arm model by Jesse (scaled to 105%), Hand model by Gordon Tarpley, Hatchbox PETG, 0.2mm Layer height

First eye prototype, LEDs are too yellow, and maybe a little too bright.

 

[thegnome]

wow, amazing work.

 

[thegnome]

Heres a question, how coarse is the plastic?

 

[JesseM]

Looks great. Keep the pics coming.

 

[TK-326]

Looking good! That filament is much shinier than the gold Hatchbox I used.
I built my animatronic 3PO using Jesse's files, plus some from Tim O'Sullivan.
Animatronic C-3PO

 

[Conqueror_Worm]

Heres a question, how coarse is the plastic?

Most of the prints have a 0.3 mm layer height

Looking good! That filament is much shinier than the gold Hatchbox I used.
I built my animatronic 3PO using Jesse's files, plus some from Tim O'Sullivan.
Animatronic C-3PO

I saw that, that is really cool!

I am getting very excited, I never thought I would have a 3PO, let alone BE a 3PO! I think the last time i attempted to build one, I was in 4th grade, and I used cardboard boxes, cans, and paper mache. I wonder if there are any pictures of that abomination...

A quick test fit (this is going to be a very warm costume)-

I've been experimenting with the eyes, but I haven't found a configuration I like yet. In the above image, both eyes have yellow LEDs, but one eye has a white backing, and the other has a black backing I bought some warm white LEDs, and they really help tone down the orange color, but now the eyes seem to have a green tint.
Warm white LEDs with gold backing:

This is pretty much the current state:

My girlfriend commented that the apartment is starting to look like a sandcrawler. That's a compliment, right?

 

[Conqueror_Worm]

My 3D printed antenna is extremely fragile, so I decided to try making one out of brass tubing and washers. It worked much better than I was expecting! The process was pretty simple, mostly just soldering and sanding/polishing.
The hardest part was drilling the ID of the washers to the correct size. I ended up soldering a stack of washers together (super glue wasn't strong enough), placing the stack inside the drill press chuck, and very slowly bringing the chuck down over a stationary drill bit. Once the ID was correct, I melted the solder and separated them.
Many washers died to bring us this information.

 

[Conqueror_Worm]

I have an idea for the eyes-

Brass tubing is really hard to find, but copper tubing is everywhere.
I used to work at a science museum, and we did a demonstration called Gold Pennies. The basic idea is that you plate zinc onto a copper penny, then heat it so that the zinc combines with the copper to form brass plating.

So, can I scale this up, and use it to brass plate larger pieces of copper?
I don't have the chemicals that are usually used (ZnCL2, NaOH), so I tried to use electrolysis with a NaCl solution to plate the zinc on the copper-

but I didn't get a shiny silver part-

I heated it anyway, but no brass. I tried a few more experiments with electrolysis, but no luck (see copper fitting in first image). Next time I will try using oven cleaner as a source of NaOH, and try the more typical experiment.

In other news, I switched my 3D printer from a 0.4 mm to 0.8 mm nozzle, so I can print stronger parts faster. That took a couple weeks of trouble shooting, but I'm getting decent prints now.

I did complete one very important piece of hardware-

 

[Hammer3246]

Looking terrific! I plan on starting this soon myself as a static display, I was curious what your settings are with the .8mm nozzle?

 

[Halliwax]

How have I missed this?!?!

This is nuts! I’ve wanted a red 3po arm since TFA came out. I just recently learned about Jessie’s files, but how on earth did you get gordon’s band files?! I didn’t think he shared anything?

Have you been keeping track of print times? I’m just curious, I know your average proton pack print takes around 200 hours, I can’t imagine the large print times

That printer is really large too!! What a setup!

You more then half way done! Can you tell I’m excited over this?! Lol

Reall outstanding work!

 

[TK-326]

Gordon's hand files are on Thingiverse.

 

[Halliwax]

Gordon's hand files are on Thingiverse.

Get out of here! I never knew that! Thanks so much!!

 

[Conqueror_Worm]

Thanks guys!
Hammer3246
eSun PETG, Black

• 0.8 mm Nozzle
• 0.5 mm Layer Height
• 2 Walls
• 2 Bottom layers, 3 top layers
• 30% Infill
• 30% Infill Overlap + connect infill lines
• 227° C Extruder
• 85° C Bed
• 115% Flow
• 4 mm Retraction
• 30 mm/sec Print Speed
• 100% Cooling
• 1.5 mm Support X/Y distance
• 0.5 mm Support Z Distance

Moisture in the filament was the biggest problem I had. Filament that worked fine with the 0.4 mm nozzle, would crackle and hiss as it came out of the 0.8 mm nozzle, creating a blistered texture and weak prints. I ended up building a filament dryer. I dry the spools for around 4 hours (even new spools that are fresh out of the box), During printing, I leave the dryer running and feed the filament from the dryer to the printer. The prints are much nicer now.

Halliwax
Gordon shared his hand files here.
I don't have a total print time, but my first print was almost 1.5 months ago. When I was using the 0.4 nozzle, a typical print would take around 30 hours (the back half of the head was 40 hours). The 0.8 nozzle cut the time in half, and the prints are much stronger.
I love my CR-10, 12" x 12" x 15" build space!

 

[Conqueror_Worm]

Testing a C-3PO glove that was 3D printed in Thermoplastic PolyUrethane (TPU). It passes the "use the comlink" test around 1 in 4.
3D file by RoelVeldhuyzen

https://www.facebook.com/video.php?v=10101122590286927

If the above video doesn't work, try this link.

One last little update:

The knee joint is really hard to bend, I'll need to figure out a way to reduce the friction, guessing it involves many hours of sanding.
Leg by Jesse_M
Foot by TKCC71

 

[PeeWeeFan]

C_W, would you mind giving your body build or thoughts on it? Just wondering what the proper sizing might be for myself if I decide to dive into this. Personally, I am 5'11" and 185 lbs if you could give some advice on scaling of the models.

 

[Conqueror_Worm]

I'm 5' 10", 165 lbs
Head - 23 1/4". At 100% scale, I couldn't get the head to close. At 105% it feels a little loose, and I can wear it with glasses.
Chest - 39". At 105%, the chest is very tight, I may reprint at 106% if I feel ambitious.
Waist - 32". At 105%, I couldn't get the shorts past my hips. I removed most of the waist return edge, now I can just barely get them past my hips, but once they are on, the fit is a little loose.
Arms - At 100%, the upper arm is pretty tight, the forearm is big. 105% the upper arm fits pretty well, the forearm is huge. 106% is too big.
Legs - At 105%, they are too long. Reprinting with X and Y at 105%, and Z at 95%
Hands - Still testing
Feet - Still testing

 

[RoCKo]

Can you estimate what the complete 3-PO will cost or even single parts like the head?

That’s at least a whole lotta printing time, huh?

 

[Conqueror_Worm]

These are the estimates I've been using-
Head - 2 spools, 3 days
Torso - 4 spools, 5 days
Arms (both) - 2 spools, 2 days
Shorts - 2 spools, 2 days
Legs (both) - 7 spools, 10 days
Feet (both) - 1 spool, 2 days
Hands (both) - 1/2 spool, 1 day

18 spools total, at $25 USD/spool = $450
25 days of printing

 

[Mulbin]

That washer antenna is great! Could you give a full part list for it so I can get ordering brassware on amazon?! I’ve often wondered if there is a good combination of compression fittings that would make arm pistons.

 

[Conqueror_Worm]

Mulbin I bought this assortment of brass tubing, and this assortment of brass washers, then pieced it together (dimensioned drawing of antenna attached). I also bought this assortment of brass rods, for when I tackle the pistons.

A brief update:

So. Much. Sanding...