Elvis, the Printable(?) Skull

by HPaul, published

Elvis, the Printable(?) Skull by HPaul Sep 27, 2011

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Elvis has been improved! Check out "Elvis Skull Resurrected" at http://www.thingiverse.com/thing:158022

Thanks to "Cleaned Hollow Skull by ssd" for the mesh of the skull and mandible. I've cleaned up the interior a bit, attached the mandible, and added support and teeth. If anyone can further clean this up, please do.

Printable(?) because there are hanging filaments and a great deal of excess plastic on the inside that I haven't been able to lose. The drooping threads vary in quantity and placement depending on the scale. On the upside, the droops are all on the undersides or inside of the print, are easily cleaned up with an X-acto & sandpaper, and don't affect the final appearance.


The .stl file is at the maximum size that fits on my build platform. The other sizes shown were set at 75% and 50% scale in ReplicatorG and take considerably less time to print out. (The full sized Elvis took seven and a half hours to print with zero extra shells and 10% fill.)

Why Elvis?

Check out the sneer.

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I get it now. There are four separate intersecting objects in the stl file, so skeinforge gets confused as to which surfaces are inside and which are outside. The brain cavity actually has three surfaces. (Very bad! should never be odd!)

Also, it looks like the lip is not supported well, but it is ok if it is printed small enough that the gap between the support and the lip merges.

I've separated the objects using meshlab. Tomorrow I'll try to merge them properly using the binary operations in blender. (It would be cleaner in O
penSCAD, but I want to use the jaw support as a cutter to separate the blobs inside so I can delete them.)

That's great! I've tried to clean this up in MeshLab, Netfabb and Rhino with no luck. If you succeed, please post how.

I tried to clean it up in meshlab, it just isn't up to it. Really, I don't think any of these programs can do the whole job, it needs to be merged properly. Simplest, you could take it into a CSG capable cad program and union the three objects. I want to try to do better than that by intelligently removing stuff from the center.

Because of the changes to the skull, meshlab didn't extract it cleanly from your drawing. It kinda pulled out several surfaces together that didn't quite overlap correctly. So I spent the day stitching the layers together where they didn't join properly. Meshlab should have been able to do this, but the edge was just too messy for its simplistic hole filling algorithms. I ended up doing the job mostly by hand in blender, merging points and adding faces to stitch the rough edges.

I've started subtracting the surfaces from each other and deleting the left over corners, but it won't be finished today. Would there be interest in me posting partial results before it is done? Either way, I'll probably post the partial pieces eventually.

you could probably clean up all the hanging threads by either making all the bottom surfaces horizontal or no shallower than 45 degrees. This would add material probably, however.

Well, most of the hanging threads on the exterior occur under the forward points of the cheekbones and would be hard to keep from dangling without changing the appearance of the
“face”. I accepted the one for the sake of the other.

The excess complications, plastic, and hanging threads on the interior are largely the result of the difficulties I had using VectorWorks, a CAD program, to manipulate the mesh file. However, I don't claim to be an expert at manipulating eit
her mashes or VectorWorks.

Any improvements are always a good thing – feel free to clean it up.

I’ve posted the file as a .dwg file for anyone interested.

Hmmm, how would Colbert feel if we did a skull replica of him?

Alas, poor Elvis, I knew him, Horatio.

It ain't over until Elvis have walked of the ABP.

Any CSI types around here to reconstruct what the donor of the skull (would have) looked like?

I have an image enhancer that bitmaps and was able to reconstruct the image from the reflection. See attached photo for the enhanced image, and there is a tutorial here if you want to try it for yourself: http://www.youtube.com/watch?v=Vxq9yj2pVWkhttp://www.youtube.com/watch?v...

Hilarious! That's a must watch video. We have to somehow add those algorithms into replicatorg and add an enhance button!

This is nice! I can't wait untill some one make the elvis-skulsta or a elvis bobble skull