FedEx Box/Wilson Display Stand - 3 Color Inlay

thingiverse

I'm a huge fan of the movie Cast Away, and I recently returned to work at the office, but my coworkers haven't been cleared to return yet. To keep from going crazy, I wanted to create an office companion. Luckily, Babelibue had already designed Wilson, so I decided to bring the other iconic item from the movie - the FedEx package - to life as a display stand. I designed it using the Multi Color Inlay method that CHEP showcased a few months ago on YouTube: https://www.youtube.com/watch?v=0Sla-vIsvh4. This model is optimized for printing with a .4 mm nozzle and a .2 layer height. There are three separate files to load into your slicer, each containing a .4 mm wide by .2 mm tall square that serves as a registration mark. Simply load all three files, hide two of them, create a gcode file, and repeat the process for the other two items individually. This will yield three separate gcode files: one for the Fed, one for the Ex, and one for the box itself. You can refer to CHEP's video for visual reference. A crucial step is to enable Z hop, Lift Z, Retraction Vertical Lift, or whatever your slicer calls it, to at least .6 mm. This will allow the nozzle to jump around the already printed layers without damaging the print during each retraction. Start by printing either the Fed or the Ex. Once finished, remove the skirt and small registration box. Swap your filament and print the other base color layer. Remove any excess material, then finally print the box. The result will be a 3-color print with a smooth bed surface on it!