Big Hero 6 Action Figure

For 3D printing, we were asked to create an action figure with the following criteria:

1) There must be a total of at least 9 articulated joints in the action figure.

2)You must have at least two different joint designs in the print. One type of joint must be able to be printed in place, while the other type of joint must snap into place after being printed.

3) The print must contain at least one part that uses dual extrusion with multiple colors.

4) You must use the sculpting environment in Fusion 360 to create at least one part of your action figure.

Design time: ~ 15 hrs | CAD Software: Fusion 360

Print Software: Cura |Printer: Ultimaker 3+ & 2|Print time: ~18 hrs

Link to STL:

  1. Find an image you wish to convert into 3D print and upload image into Fusion 360 as a canvas, scale to size and move to central axis of plane, then click ok. To see image as background while you are working with is change opacity of canvas to ~10%, this will make it easier to see lines you are tracing.
  2. In model mode click new sketch. I used spline lines and straight lines to make the body and head. Using the revolve tool I revolved the body sketch 360 degrees and same with the head that had the stem attached to allow the neck & head to swivel.

3. I then sketched the eyes and extruded them & saved as a separate STL so it could be printed using a separate color.

4. In the sculpt environment used a quad ball to create both the arms and the legs of the action figure. Once I got the exact dimensions I liked, I mirrored quad ball to other side using the mirroring command tool.

5. I also used a quadball in the sculpt environment to make the hands.

7. Once I combined to cut the sockets with the leg and hand models on one side of the plane I mirrored the sockets to the other side. Some additional editing on these joints needed to be made after printing the prototypes. I filleted the edges of the sockets on the body & the sockets on the arm, flaring the edges allowed more range of motion. Additionally, I had to punch a cylinder that was the same diameter as the sockets through the socket that lay in the body at the shoulders and the arms were the hands would connect.

8. The joints for the legs were made in the model environment by creating a rectangle and a cylinder combine to cut into the body and use the draft tool to allow better ROM. Mirror the cut & cylinder onto the other side of the plane. Then make new rectangle create a larger cylinder to cut through the rectangle that will attach onto the leg. Combine the rectangle onto the leg and mirror onto other side.






9.Originally I wanted to make small hinge joints for each finger, but save time I decided to make one large hinge joint through the hand to act as knuckles and attach each finger to the bar. Create a large cylinder to cut through the hand with a smaller cylinder that will be the hinge. Combine to cut larger cylinder through both hands. To create the bar of hinged make a box on one side of the cylinder and use the revolve tool.

10. To make the fingers I used quadballs in the sculpt environment. Also created a tube to combine fingers together and to thicken the bar.







11. To make the hat accessory ( helmet). I draw an ellipses around the head, a smaller one and larger one. Drew a horizontal line going through the center of the ellipses and another vertical line to cut off the bottom of the helmet. Used trim tool to deleted one side of ellipses and used the revolve tool to revolve the helmet around. Then used a conic curve to punch out a spot for the face on the front of the helmet. Using the spline tool & circles sketched an ear, extruded it and mirrored to other side of helmet.











Print settings: The same prints settings were used for all prints. The body with the eyes were printed on the ultimaker 3+ and all other body parts and accessory was printed on the ultimaker 2. Everything was scaled to 80% to cut down print time.

  • layer height: 0.2mm
  • nozzle size: 0.4mm
  • Wall Thickness: 0.7mm
  • Print thin walls check off
  • temperature of nozzle: 200 Degree C
  • temperature of bed: 60 Degree C
  • infill density: 15%
  • infill pattern: grid
  • Support Generated:
  • Overhand angle: 50
  • Support pattern: lines
  • Support density:25
  • Build plate adhesion type: brim
  • material used: PLA


Body with Eyes:~15 g/ ~14 hours

Arms: ~12 g/ ~2 hours

Hands: 8g/ 1 hour

Hat: 6g/ 42 minutes


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