Digger 2.0 - Childrens Toy

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I designed this model from scratch using Fusion360 the software allowed me to test all the moving parts for correct functionality before printing.

The Digger's arm and bucket can rotate 360 degrees the arm or boom moves up and down with the left lever while the bucket moves in and out with the right lever.

The mechanical movement is achieved through some basic linkages and pivot points.

The entire model is made on a 3D printer and requires no additional hardware to assemble.

To assemble you will require the following:
Super glue
Some bulldog clips or clothes pegs to use as clamps
Some sand paper
Some needle nose pliers

Step 1: Print All the Components to Make the Toy

Using your chosen 3D printing software open each STL file. The Components are all orientated for best printing. Only the bucket requires supports to print.

I made this toy using a PrintrBot simple metal with a 0.4mm nozzle sliced in Simplify3D using 0.1mm resolution, 50% infill.

Once you have all your parts printed and cleaned up to your liking assembly is fairly straight forward.

Tip: the supportmaterial in the bucket can be removed by snapping it out with some needle nose pliers, and the parts smoothed with some sandpaper.

The parts should just press fit together but a small amount of super glue is recommended to give the model some strength.

Step 2: Assemble the Base

Starting with the base. take the 3 feet and press them into the 3 holes on the outriggers.

Then take the ring and press it on to the top of the base.

if needed a drop of glue between the parts can be used to ensure they stay together.

Step 3: Arrange the Pegs for Assembly

Arrange your pegs ready for assembly there are:
3x 12mm male and female.
4x 8mm male and female.
1x 8mm male
1x 11mm large male (no hole down the middle)

If using super glue having a number of bulldog clips at the ready will help clamp parts to gather while the glue sets.

Step 4: Assemble the Bucket and Forward Boom

starting with the bucket assemble the forward-boom to the bucket using 12mm male and female pegs.

Step 5: Boom Arm

Assemble Boom arm and 90 degree linkage with 8mm male peg

Step 6: Short Linkage

Assemble short linkage with 8mm pegs in the top hole and 12mm pegs in the bottom hole

Step 7: Long Linkage

Assemble long Linkage with 8mm pegs

Step 8: Bucket Control

Assemble bucket control with 8mm pegs

Step 9: Attach Boom and Bucket to Main Pivot

attach the bucket and boom assembly to the Base-pivot using the 11mm large male peg (no hole down the middle).

This will be a very tight fit.

Step 10: Boom Control

Assemble the boom control using 8mm pegs at the bucket end and 12mm pegs at the base end.

Step 11: Combine Upper and Lower Assemblies

Insert what you have assembled into the top of the base assembly

Step 12: You Have Completed the Assembly

Manipulate all the joints to free them up, they may be stiff to begin with but with movement they will begin to move much easier.