3d Printed 1:1 replica of the 11-foot Starship Enterprise from TOS

[phase pistol]

Just wanted to show off some incredible work by Russell Meyers. Over the past three months, he led the team that designed and printed this fabulous replica of the studio scale model. You're seeing the raw prints assembled for the first time (the rest of the ship, the other nacelle and the side of the saucer section, was printed by Frank Terribile and was not available for today's photo session). I contributed some blueprint work and decal design.

More photos here!

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The deck plan Photoshopped onto the model is new work by Matthew Cushman.

 

[Pyramidrep]

Mother of God!. What a project. That is phenomenal work.

 

[joberg]

Oh my sweet, sweet Lord My kind of Bigature!!

 

[publiusr]

Rapturous!!!

Scale up the 3 Footer to match…and the FJ (Achernar) to go with it, please!

A couple of phys.org stories you may be interested in:

“A 3D printer that can print data sets as physical objects.”

“New ultra-fast 3D printer works like a reverse scanner” from Prof. You Yang of the Technical University of Denmark (DTU).

That uses Tomographic Vat Photopolymerization (TVP).

“Since the new 3D printer uses an inverted CT image as template and simply changes the polymeric material with light rays instead of printing point by point, objects can be produced almost instantly.”

Gary Kerr, Playmates…got your ears on?

 

[t2sides]

This is really AMAZING!!! Very nice!!

Can you share more info on the construction?
Printer and materials? How many segments created? Will it be finished or intended to be separated? Will it be painted? Lights? Any support or armature? Is it a ‘master’ pattern? Will it be on display at some point?

I think a lot of us would love to hear as much as you can share on this project.
Really stunning achievement!
Sean

 

[PHArchivist]

Are you kidding me? TOO cool...!

 

[TazMan2000]

Imagine how much sanding and bondo that will require.

TazMan2000

 

[Mr. E Man]

I was just thinking that. Lots of facets to smooth out.


E

 

[joberg]

Imagine how much sanding and bondo that will require.

TazMan2000

I think that after buying your supply of sand paper + Bondo at Canadian Tire, your picture would hang proudly in their headquarters

 

[22 Stars]

Imagine how much sanding and bondo that will require.

TazMan2000

Actually not much at all. Latest process is a thin coat of UV resin brushed over the whole thing. Gives it a glass smooth surface and reduces sanding by 80%. Thanks for liking the build!

 

[22 Stars]

This is really AMAZING!!! Very nice!!

Can you share more info on the construction?
Printer and materials? How many segments created? Will it be finished or intended to be separated? Will it be painted? Lights? Any support or armature? Is it a ‘master’ pattern? Will it be on display at some point?

I think a lot of us would love to hear as much as you can share on this project.
Really stunning achievement!
Sean

Thanks Sean, it’s been a great project. Here are some details:

About 45 individual prints, typically 10x10x10” big.

Printed for my buyer, we simply bonded the centerline of the saucer with Weld 16 acrylic cement which bonds the PLA2 plastic together. Everything else is just taped together with gaffers tape and it still holds together brilliantly. The buyer will finish and paint it as they desire, and is considering lighting setups. Modern Remote Control LED kits would be ideal but that’s up to him.

I engineered supports into the pylons, cross printed for strength, and printed a few sections at over 10% infill so they are hard as a rock and very rigid. The rest is lightweight at 2% infill. There is a 1” hole running through the the secondary hull straight through the dorsal a a main stand balance point.

It will live with my buyer, but I would love to print others for conventions and public displays if anyone want to commission it!

Big thanks to Daniel Broadway for the original CG model, built for video renders, Frank T. For printing the port side and to Karl for all his graphics expertise as well as Gary K. for advising me in making it as accurate as possible.

 

[22 Stars]

I was just thinking that. Lots of facets to smooth out.


E

No more effort with modern techniques than filling bubbles or warps in resin garage kits. Thanks for liking the build!

 

[22 Stars]

Mother of God!. What a project. That is phenomenal work.

Thanks!

Russ

 

[22 Stars]

Are you kidding me? TOO cool...!

Thanks man!

 

[22 Stars]

Rapturous!!!

Scale up the 3 Footer to match…and the FJ (Achernar) to go with it, please!

A couple of phys.org stories you may be interested in:

“A 3D printer that can print data sets as physical objects.”

“New ultra-fast 3D printer works like a reverse scanner” from Prof. You Yang of the Technical University of Denmark (DTU).

That uses Tomographic Vat Photopolymerization (TVP).

“Since the new 3D printer uses an inverted CT image as template and simply changes the polymeric material with light rays instead of printing point by point, objects can be produced almost instantly.”

Gary Kerr, Playmates…got your ears on?

Thanks sir. Gary helped me some advice throughout the project.

 

[22 Stars]

Oh my sweet, sweet Lord My kind of Bigature!!

Lol thanks sir!

 

[Mr. E Man]

No more effort with modern techniques than filling bubbles or warps in resin garage kits. Thanks for liking the build!

Loving the build!


E

 

[BorginanAlcove]

nice work!!! that is really cool!

 

[StevenBills]

Thanks Sean, it’s been a great project. Here are some details:

About 45 individual prints, typically 10x10x10” big.

Printed for my buyer, we simply bonded the centerline of the saucer with Weld 16 acrylic cement which bonds the PLA2 plastic together. Everything else is just taped together with gaffers tape and it still holds together brilliantly. The buyer will finish and paint it as they desire, and is considering lighting setups. Modern Remote Control LED kits would be ideal but that’s up to him.

I engineered supports into the pylons, cross printed for strength, and printed a few sections at over 10% infill so they are hard as a rock and very rigid. The rest is lightweight at 2% infill. There is a 1” hole running through the the secondary hull straight through the dorsal a a main stand balance point.

It will live with my buyer, but I would love to print others for conventions and public displays if anyone want to commission it!

Big thanks to Daniel Broadway for the original CG model, built for video renders, Frank T. For printing the port side and to Karl for all his graphics expertise as well as Gary K. for advising me in making it as accurate as possible.

Daniel's a member here. Paging DanielB