TIE Fighter Model
A compact, 3D-printable TIE Fighter inspired by Star Wars, designed under strict material and envelope constraints. The final assembly used a three-part split (body + two wings) with a peg-fit interface and a locking screw to improve rigidity while preserving wing maneuverability.
Overview
This project focused on translating a recognizable sci-fi vehicle into a printable, small-form assembly. Because the print volume and total material were limited, the design was intentionally modular: two wings and a central body, joined via a peg interface and secured using a screw.
The goal was a clean aesthetic (minimal visible “mechanical” clutter) while still ensuring the parts assembled smoothly and stayed rigid in typical handling.
- Limited total material usage
- Parts must fit within a restricted envelope
- All features above minimum printable thickness
- Assembly must be repeatable without breakage
- Maintain a “sleek” look consistent with the reference
CAD Approach
- Extrusions for side panels
- Extrude cuts for windows and wing holes
- Revolves for the main spherical form and rear detail
- Mirror features for symmetry
- Shell to reduce material and support powder removal
- Wing plate and peg created via extrusion
- Cut features to create the screw pathway
- Fillets added at peg bases to reduce stress concentration
- Screw modeled using revolves (rod + bulb)
Interlocking & Tolerance
The primary joint was a peg-fit: cylindrical pegs on the wings insert into cylindrical holes in the body. A secondary screw passes through a cut pathway to lock the full assembly, reducing looseness and helping the model hold alignment.
The initial peg/hole fit was slightly loose in the straight alignment, which led to separation without the screw. With the screw engaged, the assembly behaved as intended, with good retention and still allowing the wings to rotate.
- Tighten peg/hole tolerance to improve straight-alignment retention
- Shorten the screw rod so it doesn’t protrude beyond the intended geometry
- Run additional fit trials to balance assembly ease vs rigidity
Gallery
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