Illuminated Dalek NSD 10cm / 4" Hemisphere, Hollow for Disco Dalek

thingiverse

A Friend of L3-G0 Needed Disco Hemispheres for Party Time! It's not clear if we'll use these hemispheres for fun or just as a test, but we had to show that the idea can work. Printing 56 of these would take forever, so maybe we should look for easier 100mm ones. You could also use this design as an ornament, and I have more details on that in my Instructions below. Here are some cool YouTube videos: Glowing Hemisphere - http://youtu.be/MIjtJkc8ZHA L3-G0 & Dalek Clara - https://youtu.be/R9TgYUSNmPU Help me out! Support my designs! P.S. If you like what I'm making, please visit my Lego R2-D2 blog at L3-G0.com and spread the word by sharing a link on Twitter or Facebook! Every visitor counts! **Instructions** This is a 100mm hemisphere and an "Oil Seal" surround to go with it. The surround has a space for a WS2812B LED on a 10mm chip carrier, along with a small channel for some wires. If you want both the Surround/Hemisphere, print the unannotated hemisphere first. It's got a 5mm lip that fits snugly into the surround. I've included a 10mm lip if you need it for other mounting options. The scad files let you adjust the supports if needed. My translucent ABS at .2mm layer height took about 2 hours to print. The surrounding was printed low resolution because there were some lines on the "real" one, but this way takes an hour. There's a centered version without the LED, or one with the LED that needs supports. There's a tiny hole for the WS2812B LED in the middle, and also a 10mm carrier underneath it, plus a channel for small gauge wire to hook them up. Assembly is a bit of a challenge. **Assembly** I added one or two holes into the surrounds so you can hold an M4 bolt using them. There's space under each one for a 1mm deep washer that will keep from cracking when tightened. That washer needs to be less than 14mm in diameter. Then there are holder plates to grasp the nut and head on both sides, letting you gently twist while installing it into its home. **How-to Install:** Step 1) Place surrounds onto your Dalek model & mark drill the holes for each of them. Step 2) Connect wires from an LED (if using), so they won't come undone easily; Leave some slack between wires too, when installing bolt from outside part first. 3.) Insert bolts from outside side while holding a head and/or cap using the tiny plate to grasp on both ends. Use this or you might end up getting frustrated trying! After installing surround, insert washer if required. Step 4) Glue Hemisphere onto surrounding material; make sure everything's aligned properly! 5) Before adding it all back onto Dalek Model itself remember there is an LED component so take a look & secure it safely first (use sticky tape/gum or else!). 6.) Screw Surround/Hemisphere/LED parts firmly with M4 screws inside from opposite sides carefully place, once done your friend will surely love his Disco Sphere! Design This project consists of main Hollow Hemisphere which resulted by the subtraction operation of nested spheres: interior dome was made slightly lower just in order create better thicker upper layer but it turned thin - this didn't deter results.