Parametrized Prusa Face Shield RC3.2 Headband Stack with supports for Fusion 360

thingiverse

Here is what I've been up to for the past few weeks. I enlarged the nubs' sides and chamfered faces by .5mm, while keeping the top and bottom faces unchanged. The height of the band has been reduced, and all unnecessary markings and features have been eliminated. A built-in support structure was also added. When changing the height, you'll need to use the history marker to recalculate two features: Extrude 4, which joins all the supports, and the final Combine that selects all headbands to be included in Component3:1. I export the resultant body from Component 3:1 as an STL from the Design workspace at this point. It seems like .3 layer height and a double gap (.6 gap) is my printer's sweet spot, but your mileage may vary. PrusaSlicer complains if the bandshorten parameter isn't a multiple of my layer height. Gap fill is undesirable for speedy printing, so I try to trick the slicer into putting extra perimeters into the forehead inner band by parametrizing its thickness. For 3 perimeters @ .5 line width, the ratio of inner band thickness to line width should be ~3.2 in order to get 4 perimeters on the inner band. Again, you'll have to experiment. One of the last OffsetFaces is the nub enlargement, just in case you hate that feature and want them back to normal. Assuming your printer is well tuned, the supports will easily snap away from the surface and bend off. Light treatment with a utility blade will separate the headbands at the gap interface. In all, I get ~1.25hrs per part with this model. Note: The .obj is just there for show - you should export your own model from the CAD. PLA seems to like a shorter gap distance, .4-.5mm, while PETG prefers .5-.6mm gap distance. Changelog: 15/5/20 Cylinders were put through supports @ top of stack to ensure boolean combine results in one solid body. Added a shorter, buggier stack with side elastic affixing features shifted down.