Thursday, December 31, 2020

Welcome to Charlesworth Dynamics

I am a hard surface 3D modeler and printer with a specialty in designing assemblies. For 12 years, I was the Head Repair Technician for NYU Film & TV - responsible for the repair, maintenance and processing of all production equipment.  Recently I relocated to the San Francisco Bay Area where I am the 3D Printing & Fabrication Specialist on Tested.com.  I use my hands-on knowledge and sensibility, to design working 3D printed assemblies combined with actual hardware where appropriate.

This was originally an archive of my 3D modeling and printing thesis (see Octopod below) for a Masters of Science in Digital Imaging and Design at NYU.  It has since grown into much more, documenting my 3D printing as well as 'analog' projects which cover anything from camera repair to building Star Wars blasters.  I felt it was appropriate to combine the two since I constantly bring the digital world of 3D modeling and printing together with real-world hardware and construction.

SOME HIGHLIGHTS --

Adam Savage's Inventern

I won a competition to assist Adam Savage of MythBusters on a project.  I recount the experience for Tested.com.






3D Printing on Tested

I cover 3D printing as well as build projects for Tested.com.

Tested is run by Norman Chan and features Adam Savage of MythBusters.


Cutaway Lightsaber

In conjunction with Formlabs, I designed a custom cutaway lightsaber.
See how it was designed on Tested.
Watch Punished Props build and paint one!

Download print files here.




Ghostbusters Ghost Trap

See my fully 3D printed Trap on Tested.

Download & print your own.

Get the hardware to put it all together.

Get assembly guides.

Octopod Underwater Salvage Vehicle

My thesis project which I designed, printed and built.  Make sure to look at past posts which go into great detail about the modeling and printing process.





The Octopod won an Editor's Choice Award at Maker Faire New York 2012 and is featured on the MAKE site and in their "Ultimate Guide to 3D Printing" issue.

It has also been featured on the Objet site and with great pride on Tested, an awesome site which features my hero, Adam Savage from Mythbusters. (Seriously, check out the videos of Adam's workshop).


The Scuttlefish
(aka Gowanus Monster)

I designed and modeled this for an animated film by Bold Machines. It's definitely in the same fleet as the Octopod.
Read about it here.
Download files here.
Buy one here.

TARDIS Kits
3D printed TARDIS kit.  We are offering a regular TARDIS, Half Wolf TARDIS (shown) and a lighting upgrade package (soldering skills required).

They are up on our Etsy Store, so check it out.

See my full write-up of how the TARDIS was created on Tested.com.



Iris Box v3

Update to my original iris door box, derived from the Octopod moon pool door.









Buckaroo Banzai Jet Car

My other on-going project is the Jet Car from one of my favorite films, The Adventures of Buckaroo Banzai Across the 8th Dimension.  It was my first 3D print and I did a full write-up of how it was done for Tested.com.

The Jet Car was on display in Vienna, Austria for Vienna Design Week 2012.




Iron Man Arc Reactor

Ongoing project to 3D print the MK I Reactor.
3D Prints - Misc

The Octopod and Jet Car are my two major creations.  These are my other creations which range from useful to fun.  Most of these were printed on my Thing-o-matic or Replicator 2X at home.




'Analog' Projects

A selection of hands-on projects I have tackled, including a Stormtrooper Blaster.













FAQ

Q:  What did you go to school for?
A:  I went to New York University's Center for Advanced Digital Applications in the School of Continuing and Professional Studies for a Masters of Science in Digital Imaging and Design. Whew.
I originally intended to be an animator, but started modeling more and then found 3D printing and that was that.

Q:  What do you want to do with 3D printing?
A:  Ideally I would like to work in toy design or prop fabrication.  I like combining digital models with real-life hardware.

Q:  Are the Octopod & Jet Car for sale? 
A:  There is a lot of interest in the Octopod, but at this time it's not for sale for a variety of reasons.  Mainly, it's very expensive to print and would drive the price up quite high.  In addition, I have learned a lot since first designing the Octopod and it needs a many updates to be ready to sell. The printing material has a tendency to sag over time and my original Octopod has a lot of fit problems now, parts need redesigned to fix this and bring print costs down.  Basically, the Octopod needs rebuilt from scratch - it's going to happen but will take awhile.

The Jet Car is much closer to being printed, I'm currently working on a revised version to beef up some parts and bring down print costs.  The plan is to have versions at 1:25, 1:43 and 1:64.

If you would like to be added to the mailing list for the Octopod or Jet Car email me.

Q:  How about the Iris Box, can I buy one of those?
A:  Yes!  I have iris boxes, TARDIS kits and other good stuff on my Etsy store.  If you have a 3D printer, you can also download it from Thingiverse and make one!

Q:  Can I have your files so I can print my own?
A:  At this time, other than what I have up on Thingiverse, I don't plan on releasing the files for anything.  These models have taken many hours to design and I'm not quite ready to let them go.  Thanks for asking.

Q:  What do you model your stuff in?
A:  I use Cinema 4D, a professional production suite.  It has great modeling tools and recently added the ability to model in scale.  I am not an organic modeler, but I do use ZBrush for some stuff, particularly decimating the model (reducing polygon count), I then use netfabb for STL clean-up.

Q:  What do you print on?
A:  I typically use the Objet Connex500 which uses photopolymer jetting (deposits resin on print bed, hardens with UV light) and can print 2 types of material at the same time.  I have recently gained access to a 3D Systems ProJet 7000 and these are by far, the nicest prints I have done.  I have also used ZCorp machines which uses a plaster-like powder - these are the ones that can print in color.  I have used Shapeways with nice results using their Strong and Flexible nylon material.  I also own a MK7 MakerBot Thing-o-matic and Replicator 2X for home printing.

2 comments:

  1. Do you have after market products on your MK7 MakerBot or your Replicator? How do you make higher quality prints with your desktop printers? If NOT, what do you implement/tweak to print in suck fine detail?

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    Replies
    1. I have a few replacement parts on my Replicator 2X, the biggest and best is an aluminum x-carriage replacement from http://shop.raffle.ch/. But I feel that the immediate things you can do are machine maintenance and custom printing profiles. Making sure all your belts are tight, in alignment, no screws loose, lubricate the rods, etc can make a big difference.

      When you get a printer, the software will have 'best guess' settings which will try to print well for all filaments. In reality this won't work since each roll of filament might have a slightly different diameter, material properties, etc. If your software gives you the option, it's often beneficial to tweak settings, which can be intimidating. And easy first step is get a pair of calipers and take a few diameter readings on your filament and enter that in a custom profile. Printing slower will often help with small detail and printing with only 1 shell can help - but it will also make the print weaker.

      Also keep in mind, not all printers are created equal and some will just never print as well.

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