The final project for my 3D printing class was to create a figure with articulated joints. I chose to create Sponge Bob because he is part of my childhood.
I started building the arm first. I began by creating a sketch with 3 circles with the diameter as 10 mm, 10.50 mm, and 11.50 in which all of the circles were built from the same center point.
Then I drew a line to separate the circles in half and a diagonal line from the center with an angle of 71.6 degrees. The reason why I created those lines, is to make it easier for me to trim the bottom part of the circle and the outside of the shoulder joint.
After I trim the lines, I clicked on Revolve localized in the Create menu. After the Revolve window pop up, I selected the two faces and the y-axis to revolve the sketch and pressed enter.
I wanted to make a sleeve for his shoulders, so I drew a 5.75×5.75 square from the circles center point and I drew a 5.20×5.50 rectangle inside the square as it shows in the picture.
Then I Revolved the tiny space between the circle and the square with the revolving setting in the picture.
As soon as I finished the elbow joint, I started making the arm by drawing a circle with a 5mm diameter at the bottom of the shoulder. In order to do so, I selected the bottom of the elbow as my construction plane, instead of using the original ones.
After I drew the circle, I Extruded it by pressing the letter E on the keyboard. I pulled it 17.5 mm downwards to make the upper arm and subsequently, I started planning for the elbow joint.
I drew those shapes in the picture using the slot and line command and then I extruded them 7 mm downwards.
Then I drew a 2.3 mm diameter circle inside the wall that I created the on the last step, and I extruded that circle until it connected to the other wall.
In order to complete my next step, I moved the original y construction plan 1.60 mm to the side. Then I drew two circles from the same center point with the diameter of 4mm and 4.30 mm on the construction plane I just moved. After that, I extrude the area between both circles using the settings in the picture below.
Then I moved the construction plane 5.5mm as it shows in the picture below. I drew a 2mm diameter on the plane. Consider that the next 3 circles are going to be drawn based on the same center point as this one.
Afterward, I moved the plane 1.5mm and I drew the same 2mm diameter circle on it.
Then I moved the last construction plane 0.5mm and I drew a 2.5mm diameter circle.
Next, I moved the last construction plane 1.50mm and I drew a 5mm circle on it. After that, I used the Loft command under the Create menu to connect all the circles.
To finish the arm I extruded the biggest circle 15 mm.
To make the Sponge Bob’s body I entered the sculpt environment and created a Box, which can be found under the create menu. Then I created 2 spheres inside the body to make the eyes, and to make the nose and the cheeks I created cylinders and close them cylinders tips by using the Fill hole command under the create menu. I played a little with the nose to get the shape that I wanted. I also moved the edges a little to get the wavy effect of a sponge.
My next step was to create his mouth and teeth. I drew the mouth then I extruded it 5 mm. Then I drew the teeth and extruded the teeth 4 mm.
My last step for his mouth was to create his tongue using the Slot tool and I extrude it 2.5mm.
My next step was to separate the body into two parts, and in order for me to do so, I drew a line where I wanted to separate the body and I used the Split body tool under the Modify menu.
Then I copied my first shoulder joint into my legs joints by right-clicking on the ball and selecting copy/move. Then the menu will pop up, and after you select the body you want to copy, you need to click make a copy at the bottom of the menu.
My next step was to move the original construction plane of the y-direction 18.50 mm to the side. Then I did my first step again, which was to create the out part of the joint by drawing the three circles using the same measurements, cutting them in a half and cut the half in an angle. But this time, I will revolve only the out part because I already have the ball joint.
To make his leg, I did the same process on the arm, although the leg was a little thicker. I moved a horizontal construction plane and leveled it to the joint and drew a 6mm circle. Then I extruded the circle 17mm. My next step was to draw a square on the bottom of the leg, in which the corners of the square are aligned with the extremities of the circle.
Then I extruded the square and the little spaces highlighted on the picture -7mm.
Just like I did for the arms, I created a 2mm circle on the wall and I extruded that circle until it reached the other wall.
Using the same plane construction I used to create the out part of the joint, I drew two circles of 4mm and 5.3mm diameter. Then I extruded the inside area using the settings in the picture below.
My next step was to create a 2mm diameter circle on the bottom of the leg like in the picture. Then I moved the plane 2mm I drew another circle but this time 3mm diameter.
At next, I moved the plane 1mm and I drew a 6mm circle and I connected all the circle using the Loft tool.
Then I extruded it 15mm.
To make the detail on his body that looks like holes, I drew different size circles all over his body and extrude them using the cut tool inwards.
To make his hips move, I moved the construction plane as it shows in the picture.
On the plane, I drew a 9mm and a 16 mm diameter circles. then extruded it until it reached the superficies.
Then I extruded them in the opposite direction as it is shown in the picture.
After I finished creating the hole, I extruded only the smaller circle like the picture shows.
My next step was to enter sculpt environment again to create the hands and feet. I used the box and quadball shapes to make them, and I play a lot with the surfaces to achieve the results I wanted.
And this is the final result of my Sponge Bob.
This design was created as part of the University of New Hampshire’s ET401 “Introduction to 3D printing ” course. You can find design plans for this projects and many others at https://www.thingiverse.com/thing:3277824