My first mini-figure was okay but I like this one better(here's the link for the first one) . The first one would have been a pain to optimize for 3d printing. When I created it I had no idea that there was a minimum thickness for walls and wires. This model required minimum tweaking. I also changed the joints to snap fit ball joints for better articulation.
Before I start you should note that when I was taking screenshots I didn't know about the minimum thickness requirement. So some of the measurements must be tweaked.
Also always take into account a 1mm rod won't fit into a 1mm hole: so you must take into account tolerance. When you make the ball joints they are supposed to slide into the body so make sure the square holes are a little bit bigger then the joint.
I would recommend reading this article on designing snap fit joints here. Unlike the what I said above snap fit joints don't need to be different sizes. They should just fit together perfectly.
This mini-figure has six points of articulation. There's a head joint, two arm joints, two leg joints, and the waist should pivot.
The mini-figure turned out nice. It was smaller then I imagined it would be, and the ball joints would not slide into the body like I was hoping so I had to break out the glue gun. I glued the ball joints to the body and waist, then glued the waist to the body, and the sword to the hand. After that it worked out pretty well. He stills needs some tweaking(That means look out for version 3).
Link to model click here.
Step 1: Dimensions
The heads Length,Width, and Height is 8.659mm.
The arms and legs have a width of 4.329, length of 13.854, and height of 4.329.
The body is two arms or legs put together.
After you make the dimensions this snap them together.
Step 2: Then the Ball Joint
Step 3: Creating the Joint for the Arm
Now your going to make the connection between the arm and joint. Sketch a square positioned on the uppermost part of the arm facing the body. The square should be just a little bit smaller then the circumference of the ball joint. Negative extrude the sketch to create a square hole. Copy and paste the ball joint then snap the joint into the square hole and subtracted the joint from the hole. Now just position the joint and arm.
Step 4: Creating the Waist and Leg Joints
Making the leg joint is the same as the arm joint.
Step 5: Connecting the Waist and Body
Then I copy and pasted, and subtracted. Remember you have to account for tolerance so make sure the cylinders radius fits into the waist and body. If not then copy and paste the cylinder, the scale the copy up by .01 mm and subtract it from the waist and body.
Step 6: The Head Joint
Step 7: Pegs
When positioning the peg holes keep in mind the minimum wall thickness.
Step 8: The Sword
Step 9: Dissassemble
Step 10: Troubleshooting for Shapeways
The sword blade and hilt was also to small so I just scaled the blade and hilt out some.
The hands wall thickness in the front was also too small so I used the push pull tool and pulled it back .4mm then pulled the face across from it back .4mm.
Step 11: Pictures of Test Print
All in all I like the way it turned out, with a little bit of tweaking he will be sales worthy on Shapeways.