Millennium Falcon box for X-Wing Miniatures game

thingiverse

Finally got around to building a custom case for my Millennium Falcon model to use with X-Wing miniatures game. The case keeps it safe and takes up less space than the nice clear plastic it came in originally. Since the part is large and the lid requires added strength on the Z-axis, good layer adhesion is crucial for this print. The box could split as it cools (a common issue with big prints), so I followed these steps to enhance layer bonding: 1) Turn up the nozzle temperature to get the layers to melt together well. For this print, I used ABS at 255 C. 2) Enclosing the printer helps reduce cracking caused by rapid cooling. Even a makeshift setup like mine (taped-up fabric made from worn-out t-shirts) can make a big difference. With these precautions in place, my print had no splitting and only minor lifting on one corner. To minimize failure points, I suggest printing the lid with 100% infill, as the hinge and clasp areas are likely to be the first to fail. This won't significantly increase plastic usage, just a tiny bit more in those areas. Check out some of my other box designs here: http://www.thingiverse.com/thing:744621 Post-printing tips: The hinges are designed to fit snugly. You can see on the model that I made the parts on the lid come to a point, making it easier to push them in. Depending on the print quality, you may need to clean up these edges with a file or exacto knife for a smooth snap together. I also like to apply some acetone to components where delamination is likely to occur, such as the clasp area. This weak orientation can cause issues, but a light application of acetone will help bond the exterior print walls. Just be sure to let it cure overnight and avoid sealing the box shut!