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3-Face pencil cup/desk ornament

by the_digital_dentist, published

3-Face pencil cup/desk ornament by the_digital_dentist Dec 15, 2013

Description

This is a pencil cup using a model of my own face on 3 sides.
The face model was extracted from a cone-beam CT scan that was done on my head to aid in treatment planning for orthodontics (braces) in 2007. I extracted the soft tissue using DeVide, then exported as an STL file. The STL file was brought into Mesh Lab where extraneous stuff (internal anatomy- sinuses, etc.) was removed, leaving a 3D zero thickness surface, saved as an STL file again. That file was brought into Blender where the edges were cleaned up, some surface problems smoothed, and the back closed.
There will be more designs from the same CT scan- I can select bone, etc, so there's an infinite range of possibilities.

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Instructions

Update: the latest version of slic3r is much smarter about generating support material and only generates support for this build under the chin and nose. It's much easier to clean up after printing!
This mash-up was made in Sketchup- the face STL was imported, then turned into a component, then duplicated and rotated to fit around the triangular cup. The cup was also saved as a component. Each component, in its final position, was exported as an STL file, the all four STL files were loaded into Mesh Lab and the file flattened so all four components were on the same layer. The whole thing was then exported as an STL file and reopened in NetFabb for final repairs.
The stl file was sliced using slic3r with 0.25 mm first layer and 0.2mm layers after with rectilinear grid support material at 2.5mm spacing and 15% rectilinear infill. I printed using Coex3D magenta ABS with the first layer stuck to the bed at 105C and then dropping to 75C for the remainder of the print. I used 3 solid top and bottom layers and 2 layer walls. The print was made on MegaMax and took about 9 hours.
I have uploaded the original CT scan files for anyone who wants to try playing with them. Just DL and unrar the archive.

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