Giant Lego Darth Vader

by mattk007 Feb 14, 2013
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Can someone tell me what the body fringe is supposed to be for???

Hiya, The Body Fringe is a carry-over from the donor lego fig, which was x-mas themed. I kept it because I was too lazy to completely re-design the body.
I removed it on subsequent figures, but left it on Darth Vader since I felt he looked better with it ...

Just looking at the files, I don’t see how the hands fit into the arms or the arms fitting into the body

Hi, The hands push into the arms, and the arms are held on the body by the pins...

this is so cool!!!!!!!

the snap hips is not properly designed : the printer printed under "vacuum"!
Need to modify the printer setting to print the snap hips with brim and very high raft
Can you help to finish please : this is the last part to print to get the Vador!
Thank you!

Finally, I succeeded in printing the last part "snip hip" : with printing parameters (print support material)

Hey, nice model. I have two questions:
1) how are you supposed to connect the arm pins to the body itself? The holes and pins do not look like they belong to the same concept !?
2) whats up with all the jagged polygons in the helmet? It looks like it was mangled by meshmixers reduce function or something. This will sure look bad on final prints as a lot of detail is lost. Why no sharp edges?


I haven't built this one but assume it's the same as other similar designs, the arm pins get pushed through from the inside of the body, it's a little tricky but you will need a pair of needle nose pliers or something and push them out from inside.

I'm struggling with fit and finish here. I've calibrated my printer especially for this job, ensuring I'm printing a perfect cube. I'm printing in PLA.
Here are the issues:

  1. The lightsaber hand-hold doesn't fit the hand. In the designer's photo the hand holds onto the ribbed base of the light saber, but the hand should fit the smooth area between the ribbed base and the hand guard. The hand interior dimension is 11.85mm, the saber hand hold is 11.44mm in diameter
  2. The light saber rod fits very, very loosely inside the saber handle and must be glued. Interior of the handle is 10.77mm, rod is 9.41mm
  3. Helmet is huge for the head
  4. arm pins are super small compared to the openings, and don't allow good friction; the arms flop on the body. One pin wouldn't hold the arm close to the body at all.

Are others having the same issues?

My arm pins are snug but the pins seem too long. The arms have a gap between the body and "armpit" area. Maybe 2mm or so?

the head needs remixed its too long front to back. Didnt even notice til I was done.

Guys if things fit tight on these models, IE head wont go on to the post, arms dont go in the holes. there is a simple solution.
Grab a heat gun, blow dryer and slowly warm the peg. And I mean slow. then tart to spin it onto the mating part slowly, turning it. it will start to slide on. you will essentially marry the 2 pieces together. I printed 5 regular of the lego guys and all pieces fit differently, even though I printed multiples on the same build surface. Probelm is with most circle they arent circles! they turn into multisidd polygons and have straights between each vertex thus making them just .1or so mm to big or small for id circle.

my porblem is my slicer wont show the added on support for the lightsaber

I used sandpaper for finish work. 100grit seemed to do the job VERY well where fitment was an issue. There's other issues as well with certain parts, but that's on me.

thanks for the download. i am having problems printing the snap hips . i am new at printing. when i start printing it some parts are in the air and have nowhere to stand. what can i do?

The easiest way to print is lying flat (as if the lego figure was face down). You will also need to use supports for the pegs that hold the legs on.

thanks alot it turned out great. my son is only 8 so i have to step in and help with things like that.

HI there,
Very nice design, I want to make a lamp of it, can ir be scaled up 250% ? and still fits


What's the best way to print the Snap Hips?

I had a couple issues. The head is good and fits on the body nice and snug but the helmet is loose and falls off a lot. I fixed it but wrapping a little clear tape around the top of the head. I might try my hand to remix it to be a tab bit tighter. Also the hands need to be shaved down a bit to fit and sometimes cracks the arm but that my be my cheap filament. Wish they were round but that's just me.

I printed one and finished he is about 160mm tall :)

Does it come with a cape?

I just cut a material cape , but other have printed them... quick search on thingiverse will reveal some


Remixed Cape for Giant Lego Darth Vader
by BB1980
Giant Lego Darth Vader Printed Cape!!

Great model, my kid will love this when it's ready! I worked from the bottom and up and after printing the arm pins and ran into some problems.. No matter what setting I used the arm pins was impossible to fit into the hole of the body. Don't know if it was my slicer or not but anyways, if anybody wants to print this using Flashforge's Flashprint-software these pins will work great. :)


Giant Lego Darth Vader - Arm pins for Flashprint

Having a hard time with the Hilt..it will not print.. kind of starts .5 millimeter up and the filament wont attach with the printer bed.
Have no issues with any other parts.
Please help me understand what the problem is here???

Did you solve this? It is the doing the same thing on my TAZ 5.

Never had this specific issue before, but the part is not symmetrical, so have you tried flipping it upside down?

Do you have g-code for this print? I love the idea, but I can't get it to work without the g-code. I have a Leapfrog Creatr if that is useful knowledge at all.

g-code is often customised for different printers, and is created by the software you use to enable to adjust settings (wall thickness, fill density, build resolution etc... )
I see that Leapfrog recommends Simplify3D software to use - otherwise there is other free software to do this. (http://replicat.org/generators)
Good luck

Realy wonderful!

I finished assembling, will load photo soon.
The arms hole for the hand, are intentionally made of the same diameter of the pin of the hands? 0.1/0.2mm difference perhaps would be easier to manage or creates to much clearance?

Different printers handle the tolerances differently, so trying to find one that works for everyone is unfortunately impossible. The hands need to be a press fit with this design. Maybe using the snap design as used on the shoulders and hips would be better ....

Love it. But I have cracked 3 sets of legs trying to snap them together on the new hips.

My sincerest apologies... I uploaded the wrong Legs. I've uploaded the right ones now , so download the latest snap-legs and try again.
Really sorry to waste your time and material...

No, not at all. You have done a wonderful job with this. I'm just glad we have the correct part now,
Thanks for your work,

This is great and printed well, however i found his head a little small in comparison to the body and my stormtrooper print (http://www.thingiverse.com/thing:170704) , would be cool if the heat could be a helmet like the stormtrooper and have a face underneath.

by Skimbal

Thats really cool thank you

To millstb: If you like customizing, then I suggest you put an easter egg face that's not Vader's as a surprise to anyone who opens it.

Also, to mattk007: I suggest you make something similar but body and legs and arms cone together and the head comes off as a storage container.

Almost done, came out looking great so far! One issue, the light sabre. I believe something is wrong with the scaling, I've tried two different slicing programs and it attempts to print about a 1mm diameter circle.

My mistake, neither Cura nor Simplify will slice this with the bottom portion intact. Had to go back to KISSlicer in order to get a flat-bottomed part.

legs file can not be opened. Could u check it, Plz.....

Easy build... maybe print the arm supports separately at 100% infill... my original ones at 10% snapped when assembling/sanding down.
Other than light sanding required the model fits perfectly...
Thanks a lot!

Giant Lego Darth Vader Printed Cape!!

Hello! I'd like to reach you via email about running a photo of your Darth Vader in Popular Mechanics magazine. We're doing a small sidebar on 3D printing and I'd love to include yours! Please contact me asap if you can! [email protected]
Thank you!!

What issue? I have several stacked up that I havn't gotton to yet.

this was an awesome easy project to print thanks to great designing !!!

Hi, love this model. I am new to 3d printing having just gotten a Makerbot 2X for our school. With this file there is a "shift" that occurs about 15% up in the printing. The Head, arms and legs all just move to the left and finish the print. Its like something shifts the plate. I have not had this issue with others files.

Is this something I am doing wrong? Some setting? Thanks for any advice you can offer this newbie.

two potential issues: (1) stepper motors missed steps potentially due to overheating or jamming on a curled up part of your print or (2) slicer issue, view the G code after slicing to ensure the nozzle path doesn't do something funny. This can happen if the slicer tries to automatically fix a non manifold object... and doesn't do a very good job.

we need a stormtrooper to go with this!

I am a noob at 3D editing. How can I make this the exact size that I want in blender?

I'm afraid I don't use Blender, so can't help you there...

I been trying to learn how to make these lego men i been trying to design yoda and failing any luck? i know we can use everything from the vader except chest and head. I printed the arms legs frindge hands in the right yoda colors i just need to figure out how to model the chest also can we use a yoda off of thingiverse and add a hole?

I have looked at Yoda - The body can use a standard Lego torso, which I have.
Yes, the Head is available in various guises on thingiverse - so just need to size corectly and add a hole.... although none of the heads are the same as the Lego head...
The other part that needs modifying is the legs... Yoda is short! .. so a simple Hip/Leg combo is called for to stay true to the Lego design..

Iam so Excited!

Hey Any chance on Lego darth maul Yoda or Han Solo? i want to have a colection :) iam printing the Batman now at 235% its awesome.

All these are possible :-)

Would be difficult to achieve Darth Maul with a single colour though?

This is really where the community comes in - hopefully people can take these basic building blocks and add their inputs to create a collection!

Maybe Yoda will be next? Or Ironman?


umm.... Chewbacca must be next!

then u have to have Han solo lol


Hi Mattk007
Printed lovely on my replicator 2. With force (enough to almost draw blood!) I've snapped his legs to the hip, and the head to the body, but how am I meant to get those pins through the body? I've tried printing them at 95% size but a) they still don't fit through the body and b) when I forced one through it's too small to hold the arm?
I'm a bit new to all this but keen to learn - any help appreciated!

The problem seems to be the setting on your slicing software. Not sure what you're using, but there should be a setting to adjust the print margin.
One way to test, is create a defined size block and print it, then measure the actual size produced and compare - or else use a calibration piece,
In the interim, I suggest using a drill to drill out the arm holes to a size that the pins can fit through easily and glue into arms.

You can push the pins from the outside and twist until the go smoothisch. Then push them from the inside and put one layer of tejp on the part that sticks out. GIves a nice smooth movement :)

just finished mine and i love it, great print and my son will go crazy when he gets his hands on it. my turn to play first :)

Awesome model! Most of the parts are printing great without any special settings. I did have to slow my print speed down for the Pins on my Printrbot Jr. Any tips on printing the Lightsaber handle? With a slow print speed I can get about half printed before it tips over due to the angle.

What Angle are you refering to? The handle should be printed vertically ?

I'm not sure what I'm doing wrong. I've tried downloading a few times, and resliced using a few different settings but it always wants to print rod-side down like this:


Jeez this is the pinnacle of well thought out printable-ness. Perfection! My 4 and 7 yrs old boys (and I) thank you much. Cheers!

Cool, will print it to night:) Support material needed?

No support material needed :-)


you print this without support?
How can i print the Legs and Hips without Support?

That is my question, too. I didn't even try the hips piece without support. It's printing great with supports right now.

Hey I'm still new to printing and I was wondering if you could tell me what you had used for supports to help make this?

This is going on my desk at work next to a picture of my kid

Cool! How tall does he stand?

Thats 16cm of awesome. Thanks

That's what she said.