I made this at TechShop.
Step 1: Parts
- Six sheets of 18" x 18" corrugated cardboard. You can cut up corrugated cardboard boxes or you can order pre-cut sheets at office supply stores like Staples (only four sheets are shown in the photo).
- White glue.
- One 1/4" #20 threaded rod at least 24" long. You can get these at hardware stores like Home Depot.
- Heavy nuts and washers to be used as weights while gluing.
- One sheet of 1/8" Acrylic at least 9.25" x 10". Sheets of acrylic are available from plastics retailers like Tap Plastics.
- Acrylic cement like IPS Weldon-On #16. Available at plastics retailers.
- Vise attached to a workbench.
- Laser Cutter. I used an Epilog Helix 45 Watt Laser cutter at TechShop.
Step 2: Create Sketch of the Dalek Eyestalk
Step 3: Turn the 2D Sketch Into a 3D Model
Step 4: Add a Hole to the Model
The resulting Inventor 2012 file is attached to this step.
Step 5: Create the STL File
A zip file containing the STL file is attached to this step.
Step 6: Use 123D Make to Create the Slices
- I started the Windows version of 123D Make on my computer as shown in the first screenshot.
- I opened the STL file produced by Inventor using the "Import" button (second screenshot).
- 123D Make then rendered an image of the Dalek Eyestalk (third screenshot).
- I selected "Stacked Slices" under "Construction Technique" and 123D Make then displayed what the sliced model will look like as shown the fourth screenshot.
- 123D Make made the model to be 8" long. I changed the length to 22.34" to make a full size eyestalk (fifth screenshot).
- 123D Make, by default, sliced the model in a direction that was not what I wanted, so using the "Slice Direction" function, I changed the slice direction so that the slices would be based on the model's center line (sixth, seventh, and eighth screenshots).
- Using the "Manufacturing Settings" button, I changed the settings to use 18" x 18" sheets of cardboard as shown in the ninth screenshot. This resulted in a design that would use 6 sheets of cardboard and 126 slices/parts. The tenth and eleventh screenshots show a couple of views of the sliced model.
- Finally, using the "Get Plans" button (twelfth and thirteenth screenshot), I created a zip file containing .eps files for each of the sheets to be used on the laser cutter in the next step.
Step 7: Cut and Assemble the Cardboard Slices
- I imported each of the .eps files into CorelDraw in preparation for laser cutting. A zip file containing the CorelDraw files are attached.
I used the laser cutter to cut each sheet. I used the color mapping settings in the laser cutter print preferences to cut the blue part outlines and used a low power setting to have the laser cutter mark the red numbers on the parts. I used an Epilog Helix 45 watt laser cutter with these settings:
- Blue: Vector cutting: Speed 25, Power 40, Frequency 500 Hertz.
- Red: Vector cutting: Speed 25, Power 5, Frequency 500 Hertz
- A zip file containing the control file with the settings I used is attached.
- After cutting all the parts, I collected them up (second photo) and put them into numerical order (third to fifth photos).
- I put the rod in a vise and carefully slid each part in order onto the rod with white glue in between. I found I got the best results doing about six slices at a time and waiting for the glue to hold before doing the next group of slices. I used heavy nuts and washers to put pressure on the parts while the glue was drying (examples are shown in the sixth to tenth photos).
- I assembled the parts into six components as shown in the eleventh and twelfth photos. The thirteenth to fifteenth photos show the Dalek eye from various angles.
- I then glued each component together one at a time on the threaded rod as shown in the sixteenth photo.
Step 8: Build the Stand
- I created a simple design for the stand in CorelDraw (file attached).
- Using a 45 watt laser cutter, I cut out the parts of the stand (first and second photos). For the 1/8" acrylic, I set the vector cutting settings to Speed 10, Power 90, Frequency 2500 Hertz.
- Then using acrylic cement, I assembled the stand as shown in the third and fourth photos.
Step 9: Behold the Finished Dalek Eyestalk!