Some Assembly Required

With a clean workspace, a sturdy table, and most of the materials ready and waiting, it was time to really get started on the project. Assembling the 3D printer was a painstaking process. Luke and Phillip Thomas spent the majority of one day building it. Though lots more work than just buying a pre-built model, it was a great opportunity to learn the ins and outs of the machine. 

Phill:  "All the parts just fit together. This will be easy!"

Turns out there was more than just matching screws to holes. Calibrating the machine was no easy step. 

10 hours later...

Once test chips could be printed it became "Goldilocks and The Three Bears": This one's too rough, that one's too thick, that one's not square; This one's too hot, this one's too cold. Oh no! this one scratched the bed. Try, try again. Many days of failed prints followed.

Finally, Luke was able to print without scratching the bed.

 But he still hasn't figured out how to remove the prints without stripping the tape off as well.

These are the first three prototype button mounts, designed by Phillip Thomas. The buttons snap easily into the mounts, which interlock tightly with LEGO bricks.

This is a sample 2x6 layout that combines buttons with LEGO support.

With the 3D printer in action and progress being made, the excitement around here is contagious! Special shout-out to Daddy's little helper—when he wasn't throwing LEGO bricks around the garage!