So you are interested in rocketry and SpaceX or you were just browsing for a great project. Either way, you have come to the right place. This is a 1/150th scale model of the Falcon Heavy rocket that is planned to launch in late 2014. For More info on SpaceX and the Falcon Heavy rocket follow these links.
Please enjoy the project!
Step 1: Materials and Tools
To create the project you will need tools and materials shown below or substitutes that serve you the best. If you create a cool model out of PVC and tape, that is amazing as well. Please post it in the comments so others can gain ideas!
3D Printer- I used a MakerFarm Prusa I3 with white PLA filament. Like I said above, You can use anything you want! The sky is not the limit for materials because this is a spacecraft!
3D Files- They can be found here
Two Part Epoxy- Or other strong adhesive (Mixing tools are needed for Epoxy)
Sanding Blocks- Sand Paper works just as well
Various Pliers and Cutters- Helps clean parts that come off of the printer
Step 2: Printing the Parts
Print each of the parts shown with the settings of your preference. I used White PLA printed at 205 degrees Celsius with 4 perimeters (2 mm) and a fill of 20%. This weighed 300g when done cost me $9.00 in plastic.
1 Copy of- Parts 1,2,3,4 and 5 (upper main fuselage sections)
2 Copies of- Parts 6 and 7 (lower booster sections and nosecones)
3 Copies of- Part 8 (engine clusters)
9 Copies of- Part 9 (main body sections)
Whew! That was a lot of parts! glad it's over now.
Step 3: Cleaning Up the Parts
While the process of 3D printing is very handy, many parts may need some touch up. I sanded areas that were rough and cut of larger defects off with side cutters.
Process- Sand and make smoother (if you wish to).
Step 4: Mix the Epoxy
Follow the instructions of your adhesive to get the best results. My epoxy had a one to one ratio of resin to hardener. Do this in an area with ventilation because it does not smell good at all.
Pour- Put the ratio described on your adhesive into a small container that you do not mind ruining. I mixed small batches so I did not waste material (5 min is not long).
Mix- Mix! Mix! Mix! make sure it is thoroughly homogeneous.
Note: If you wash the epoxy off your hands with water quickly it normally won't irritate the skin much. Gloves are a good alternative.
Step 5: Begin Gluing
To simplify the process, glue each of the parts into small sub assemblies and then put them together.
Glue- Start putting it together taking care to follow part placement from photos.
Wipe- Clean excess glue
Step 6: Finish Gluing
Wait for the Epoxy or glue to dry before continuing to this step.
Assemble- There should be four points of contact total. Two for each booster.
Glue- Use quite a bit of glue for securing the small points
Wait- Some patience keeps it from falling apart. I let it set overnight.
Step 7: Admire Your Work
Well Done! You have completed building a model of the SpaceX Falcon Heavy Rocket. Pat yourself on the back.
Now that you have a model of the rocket there are endless possibilities of its uses.
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