My First Life-size 3D Print (Iron Man)

[lildobber13]

Over the past eight months I have been working on my dream project, a life-size Iron Man 3D print. I am still planning on writing up a longer article about my experience and the various things I did (and would do differently); however, I figured I would share some of the details as an intro.

First and foremost, I have always wanted a life-size nerd statue (I blame the movie The Benchwarmers, or the TV Show, How I Met Your Mother); either way, I have always wanted one; however, I could never justify spending $4k - $6k for a statue. Over the years I had thought about 3D printing it but I was still a novice, and I was having nothing but issues with my Creality 3D printers. Then I watched a few reviews of the Bambu X1C, and thought it seemed pretty easy to use, and I think the best way I heard it described was to think of it as a tool to make the hobby, not the tool being the hobby.

Needless to say, I purchased one, and started researching models and ways to make it happen. In the end I came down to the following:

• The Iron Man model was purchased from Gambody.
• I used the software Luban3D and watched a couple minute tutorial to figure out how to use it (I do not 3D model).
• Created a Google spreadsheet keeping track of all the pieces as a checklist.

That’s it. From there I started loading pieces to Bambu Studio and the AMS was a lifesaver. All four bays were loaded with Bambu PLA Basic Jade White, and I could just keep refilling as needed. Here is where I stand currently:

• 38 rolls of Bambu PLA Basic Jade White (approx. $721.93 based on receipts)
• Project has been ongoing for 209 days; however, I believe my printer time is closer to 700 hours since I took a lot of breaks.
• I’m using the Bambu X1C, AMS, and that’s it. No mods, no tweaking, and since I’m using Bambu filament with Bambu Studio I keep absolutely every setting stock (except I do enable Support).
• I have about a dozen pieces left, which include the left foot and left leg.

Attached are some pictures from my adventures. I am certain some of my neighbors assume I am a serial killer with the various body parts lying around.

Also, I know there will be some people that say, with the price of the 3D printer, the time spent, and filament I could have bought a statue. I’d likely argue that, since I have spent under $2,500 total (including the printer, which I will use for additional life-size statues in the future). Plus. regarding time, Luban took me about 30-minutes, and all I do is load filament, scrape off excess filament, and that’s it. At most 15-minutes a day with this project.

[lildobber13]

Also a few questions I get often:

• Yes, he is heavy’ish (around 80’ishlbs so far).
• I use Weld-On 16 plastic cement to hold it together (it’s wonderful).
• It’s scaled 8x from the original model.
• Luban did all of the work breaking up the model, adding rods, numbers, etc. it basically made me a LEGO set.
• It is not hollow, it has an infill though, I believe 12-15%, whatever Bambu settings are (I should have made it hollow to reduce time/materials; however, as mentioned, I’m a newb and do not 3D design, but I have been practicing for the next one).
• I will likely prep/prime/paint it; however, TBD what I’m doing with that.
• He is just over 6’6"
• Next print will likely be a Starcraft Space Marine or a character from Dark Souls, though I’m not sure which one, or the Master Chief.

[Josh-3D]

@lildobber13

Also, I know there will be some people that say, with the price of the 3D printer, the time spent, and filament I could have bought a statue.

I like to imagine most people around here would argue it the other way. If you had bought a statue, they would have argued you should have got a 3d printer and printed it!

I vote for dark souls!

That’s pretty cool, and ambitious. Have you had any parts that were difficult to print? Or had problematic issues with supports? I imagine at that size and with things chopped up, it might make it easier overall to print.

[lildobber13]

You’re right, that’s a valid point! This is probably my first 3D printing forum I have ever been part of, so I’m still getting used to that lol.

I would love to do a Dark Souls one, I haven’t seen many life-size statues out there, let alone any 3D printed ones. Plus, to be fair I’ll probably end up doing all three of those options in the future.

Most parts were super easy, I just changed the dimensions in Luban for 250 x 250 x 250mm, so I had a little space on all of the edges, and used either the Auto Orient or Lay on Face features in Bambu Studio and really had no issues. I think I’ve done over 100 pieces so far, and zero errors/mistakes from the models. I have been having some quality control filament issues which are causing issues; however, not with the prints themselves.

The piece size definitely helps, it makes it much easier to avoid mistakes (most prints are 8 - 12 hours on average), plus Luban auto creates plastic rods to go into the pieces, so they clip together easily and can be cemented. It’s a pretty sleek process, and I mean when I got my Bambu X1C, I did the super-speed Benchy print and immediately started printing Iron Man right afterwards, since I had pre-sliced the model while I was waiting for the Bambu to be delivered.

[lildobber13]

Here is how the pieces look through the process. Fortunate timing since I had just taken this one off the printer bed, before starting my next piece.

Here is part of the foot taken directly off the print bed.

Here it is cleaned up.

Here are two pieces with the numbers showing, and the rod/hole.

With a -0.2 tolerance on the rod, they just fit into place flawlessly.

Final piece, just need to add a little cement and they are good to go!

[drakko]

Awesome, simply awesome. Keep it up mate and leave the neighborhood worry about body parts.
On the other hand, I trust you’ve got a kid (or more) to see his/her face when this will be ready for revealing… (lol, you should see my face now, just imagining how it will look like when ready). Good job mate👍

[lildobber13]

Thank you! It’s been a fun journey and should be wrapping up this project by the end of June!

[JJTechPrints]

Simply amazing! I really need to check out Luban as it seems like a lifesaver. I will also be ordering some Weld-On 16 thanks to your post.

Now let me torment your dreams from this day henceforth, one word… Articulation.

[KanneKaffe]

38 rolls of filament. Since you are not modelling yourself, it will probably be difficult for you to create a hollow body with a 5mm thick wall. I have started doing this in the past and started making a hollow body because of the material consumption and weight. According to my calculations and those of the slicer, I would have needed 10 rolls of PLA to print a lifelike figure about 1.70m tall. It is worth optimising the print settings. Even if you print full bodies, you may be able to save up to 50% material. No matter how much you save in percentage terms, optimisation should be worthwhile given the size and quantity of filament.

Keep up the good work!

[lildobber13]

Absolutely agree!

The benefit of doing it this way was that I don’t need any additional support. It is self-standing, supports the weight, and overall, a fairly easy print.

I have learned ways to optimize it throughout the course. I like to think of this print as my intro into Bambu 3D printing, and really 3D printing in general since it has been wonderful that I don’t have to tinker with it, nor the settings.

[Dr_Operator]

This is awesome and I love that you’re using a lamp kit for the chest.

[Henlor]

Really really impressive! I love it

[Punisher]

I have to ask.
How is this even possible?
I tried printing an Ironman helmet when I was testing a P1S and it just didn’t fit.
A bunch of those prints also look like they shouldn’t fit.
Are they all printed in pieces and glued together? Like is the head actually 3 or 4 separate pieces that you glued?
Its one of the main reason I’m holding out for a competitors 350 cubed printer. I’m gonna be printing plenty of smaller things but also a bunch of full size cosplay stuff.

[Spoon]

YouTube is your friend here.
I’ve seen quite a few YouTubers do full helmets.
Depending on what helmet it is and size of printer they have, depends on how the helmet is constructed.
I’ve seen people glue parts together. I’ve seen people just print it on one go.
Some helmets that are more snug to the face, I’ve seen people use magnets to attach the front bit of the helmet.

[lildobber13]

Essentially here is the process:

1. Purchase/Download a high-quality 3D model. I chose a 1:8th Iron Man from Gambody for my model.

2. Download the tool called Luban3D, you do need either a Premium Trial or a Paid Version. You can do monthly, annual, or lifetime. I did a month and I’ll be purchasing lifetime shortly.

3. Watch a quick YouTube video on how to use Luban3D, it’s very easy: https://youtu.be/5fPirr5rGOw?si=2Wc2-dJUO0xwNggm

4. Scale each piece to the appropriate size, mine needed an 8x scale, and then run Luban3D on each piece. Saving them in the correct folders so it’s easier for you to remember where you left off. I believe I had around 10 folders, and each one had 10 - 15 pieces in them.

5. Once printed, Luban3D can print the numbers, rods, etc. needed to hold them together and then I just used the Weld-On 16 (which you can purchase on Amazon).

6. And that’s it, the modelling will be quick, rather automated (small tweaks here and there), and then it’s just a matter of waiting for the printing to be done.

[Punisher]

Right. I had to print mine in pieces thats why I asked.
My print looks like it was cut in pieces but OPs print doesn’t.
The head and foot for example look like a one piece print.
That’s what I’m trying to determine.

[joerad]

Dude congrats!! That’s great!! Can’t wait to see your next update. Start a YouTube so we can see!!

[JoshBear]

Hi,
Many models can be split and then welded together if needed. I also look for models that allow the use of magnets. All these models were printed on the X1C without too much trouble. (Note. Apart from the Iron Man Mk5 Helmet. That was a purchase :).

Regards

Josh

[johnfcooley]

I just want to say, that above all the great work, I admire the patience it takes to print a life size anything.

I would fail. Quickly.

[Spoon]

The people I see on YouTube that print the item in parts then glue them together fill the joins up and sand them all smooth. Especially the helmets as that’s how they get the nice smooth shiny look to them.
There are different ways of filling in the joints. Some use resin and then cure it, some use filler, some use a filler spray. I’m sure there are more ways that I have forgot.
Again, check out YouTube