Maui Action Figure

Here we are at the end of the semester.  I had so much fun creating all of these designs, but I have to say I am most proud of this one.  For our final project, we were tasked to design an action figure with 9 workable joints and many other attributes. I decided to create Maui from the Disney film Moana, one of my favorite movies.  Keep in mind, I created this whole action figure in Fusion 360.

I began in the sculpting environment, by switching my settings to the mode “Sculpt”.  I went to the “Create” drop down arrow and chose a box, and I made a fairly large one to begin with his torso.  I then made a smaller one above to torso in place as a head.  I then edited each piece with the “Modify” tool.  I did this by pulling up a reference picture of Maui from Google (any picture of Maui will work) and I sculpted it as accurately as I could.

I then exited the sculpting environment and started working on making a place for the ball joint to go in the torso.  I did this by creating an offset plane in line with the top of the torso and creating a sphere, which I sized to the width of the joint.  I then cut it into the torso.

After that, I started to work on the arms.  I went into the “Sketch” environment, and I made a shape resembling half of the shape of the arm using conic curves and lines.  I made sure to create a construction line on the flat edge as I did this.

Next, I revolved the shape around to create the upper arm.

Following that, I used the “Press/Pull” option to size the arm a little larger, because Maui’s arms are quite huge.

Next, I made another gap for another ball joint at the shoulder area, the same way I made one for the neck earlier.

I then went back into the “Sketch” environment and made a sketch representing half of a shoulder blade.  I went about this the same way I did with the upper arm.  I also mirrored it on the other side to make it easier to create two.

Then, I revolved shoulder blade the same way I did with the upper arm… but it needed to be hollowed out for the joint to fit.

I hollowed out the shoulder blade using the “Shell” tool under the “Modify” drop down arrow.  I then placed it in the spot surrounding the hollowed out area for the second ball joint.

After that, I started to sketch the forearm…

…and I revolved it just as I did with the shoulder blade and the upper arm.

I then created a sphere, but instead of cutting it, this time I joined it to the end of the forearm to act as a “hand”.

As you can see, at this point I started to insert my joints into my project.  I did this by creating two joints in separate projects (the ball joint to be attached after printing, and the other joint to be printed in place) and copying them into this project.

Here is the view from the other side with the shoulder blade mirrored.  I made this action figure in the center of my work environment so I could make a construction line right down the middle of Maui to make it easier for me to mirror his arms and legs.  Also, I went back in the sculpt environment and used another “Box” shape to create a hip bone area connected to the torso, which will be printed in green to represent his hula skirt.  This will also be used to connect the legs on to the body later on.

I then placed the inside of the ball joint in the cut I created with the sphere, and the ball in the head.  Since Maui doesn’t have much of a neck, this worked out perfectly.

Then, I did the same with the shoulder ball joint.

I also had to cut another sphere into the opposite side because that asset wouldn’t mirror.

Then I inserted the inside of the joint.

After that, I mirrored the upper arm to the other side.

Then I placed the ball into the upper arm.

I then mirrored the forearm and hand to this side as well.

Here, I placed the other “print-in-place” joint to connect the upper arm to the forearm.  Notice as I am placing these joints, I connect those and leave the ball joints disconnected because I won’t be printing those in place, since I want them to be removable.  I just want the elbows to be able to bend, but not be removed.

I then took that same joint and made two of them on the hip shape I made earlier to attach to the legs.

Then, I went back into the sculpting environment and made another box to represent the thigh.  I rendered that like I did with the torso and head to make it as accurate to Maui’s leg size as possible.

I then copied it to the other side to ensure his other thigh would be the same exact shape and size.

Then, I started to insert the inside of the ball joints in the same way I did with the shoulders and neck.

I then hollowed out the first joint with a cut sphere…

…and the second one.

Then, as repetitive as this seems, I made the calf the same way I made the thigh… in the sculpting environment.

I then copied it to the other side.

After that, I inserted the ball of the joint into the calves.

Then, I moved them back a bit so they wouldn’t be stuck in the joints, because as I said before, I want the ball joints to not be printed in place like the other type of joint I am using.

Following that, I went back in the sculpting environment and created a “Quadball” for the foot.  I rendered that into the shape of Maui’s large, flat feet and attached it to the bottom of the calf.

Then I copied it to the other calf.

Moving back up to Maui’s head, I made a large sphere in the shape of his hair.  I decided to make his hair as it looks in a bun to make it a little easier on myself, because if I did his hair down it would’ve taken me a million years to make all of the curls on his head, and no one wants to do that.

Then, I created another sphere with an offset plane at the end of his head to represent the actual bun.  It’s all coming together now!

Now, Maui isn’t himself without his legendary hook.  So, I pulled a PNG of his hook into my sketch here.

I then sketched the exact shape of the hook using conic curves and lines.

Finally, I extruded the shape of the hook out a few millimeters.  He now has his hook!  And he didn’t even have to travel across the sea to get it this time.

…And here’s the completed design in Fusion 360!  Clearly the hook is very small, so when I printed this I sized it up by 600% in Cura…

…and here’s the finished product!

Print Settings for Maui:

3D Printer: Ultimaker 3+

Material: PLA (Brown and Green)

Nozzles: 0.4 mm

Layer Height: 0.2 mm

Infill Density: 15%

Infill Pattern: Zig Zag

Support: Generated Everywhere

Support Overhang Angle: 60 Degrees

Support Pattern: Lines

Support Density: 10%

Print Time: 8 hours 5 minutes

Print Settings for Maui’s Hook:

Printer: Ultimaker 2

Material: PLA (White)

Layer Height: .2 mm

Infill Density: 15%

Infill Pattern: Grid

Adhesion: None

Support: None

Nozzle Size: .4 mm

Download the STL files on Thingiverse:

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