Our third project we were given during the course was to design, create, and print a fully functional lego figurine. We were given a regular lego mini-figure, and told to measure, and recreate it, because lego minifigures are so small, we had to double our measurements.
One of the hardest parts of making the legoman, was creating the waist. The design was a challenge, because it contained many odd shapes, and sizes. It was also difficult to get the measurements correct so it would fit well with the rest of the figure, as it had to connect with three separate parts. The easiest part of making the legoman were the hands. The design process was simple, and required only two sketches to create. The hands were the only part I was able to create, and print successfully in one try.
During this project I had practice using calipers, a tool used for measuring, that has four metal pieces called jaws, that slide up and down the tool. The larger are used for measuring external dimensions of an object, while the smaller are used to measure internal dimensions. The smaller jaws came in handy many times throughout this project, such as times when measuring the inside of the torso. I also had practice in using fusion 360, matter control the slicing software we use for the flashforge printer.
The lego brick, and the legoman project, has helped me better understand fusion because of the many tools, and ways you have to manipulate the shapes in fusion to create your project. There are a variety of tools in fusion, the ones I used the most in this project were the, loft, fillet, shell, offset plane, and ruler tool. Many of these tools, such as, loft, fillet, and shell, are used to distort, or change geometry. The other tools are used when working with the plane in fusion 360, for example the loft tool allows you to connect two sketches, by creating a physical object between the two selected planes. Another important skill I learned was how to account for tolerance on a 3d printer when making parts that have to join together.
During the fabrication process of the lego man I printed five legs, three waists, three heads, four arms, and two hands. To get the pieces fitting together some solutions I used to fix the parts were, resizing the object, remaking part of the piece, and checking my measurements. My favorite part of this project was testing if the pieces would fit together, it was very exciting seeing the legoman completed!
Below are a few images showing the design process in fusion 360 such as the begging sketches starting to take shape, the print inside of the slicing software, and also the finished product.