Whirligig, Dolphins

I created "Whirligig, Dolphins" for our youngest daughter who loves dolphins. As she lives in Florida, she should not have much trouble finding a windy day to enjoy this whirligig!

As usual I probably forgot a file or two or who knows what else, so if you have any questions, please do not hesitate to ask as I do make plenty of mistakes.

Designed using Autodesk Fusion 360, sliced using Ultimaker Cura 4.12.1, and 3D printed in Tough PLA on Ultimaker S5s.

Silicon Adhesive.

I acquired the following parts:

1. One 16mm diameter ball bearing.
2. One 6" length of M8 by 1.25 threaded rod with matching nut.

I 3D printed the following parts at .15mm layer height, 20% infill and no supports in Tough PLA:

1. Two "Arm, Dolphin.stl".
2. Four "Arm, Worm Gear Driven.stl".
3. Four "Axle, Arm, Dolphin.stl".
4. One "Axle, Propeller.stl".
5. Two "Axle, Worm Gear Driven.stl".
6. One "Base.stl".
7. Four "Bolt (M6 by 1 by 6mm).stl".
8. Fourteen "Bolt (M8 by 1.25 by 8mm).stl".
9. Three "Bushing, Axle, Propeller.stl".
10. One "Joiner.stl".
11. Four "Mount, Arm, Dolphin.stl".
12. One "Mount.stl".
13. One "Propeller.stl".
14. Six "Set Screw (M8 by 6).stl".
15. Two "Wave Mount.stl".
16. One "Wave, Left.3mf".
17. One "Wave, Right.3mf".
18. Two "Worm Gear Driven.stl".
19. One "Worm Gear.stl".

This mechanism is a high precision print and assembly using at times very small precision parts in confined spaces with highly precise alignment. Prior to assembly, I test fitted and trimmed, filed, drilled, sanded, etc. all parts as necessary for smooth movement of moving surfaces, and tight fit for non moving surfaces. Depending on your slicer, printer, printer settings and the colors you chose, more or less trimming, filing, drilling and/or sanding may be required to successfully recreate this model. I carefully filed all edges that contacted the build plate to make absolutely certain that all build plate "ooze" is removed and that all edges are smooth using small jewelers files and plenty of patience.

This mechanism also uses threaded assembly, so I used a tap and die set (M8 by 1.25 and M6 by 1) as required for thread cleaning.

To assemble the drive mechanism, I performed the following steps:

1. Inserted one "Axle, Worm Gear Driven.stl.stl" into one "Arm, Worm Gear Driven.stl"
2. Positioned one "Worm Gear Driven.stl" into the space between the forward worm gear towers in "Base.stl", slid the worm gear axle and arm assembly into the forward worm gear tower, rotated the driven worm gear until a gear tooth space aligned with the arm, then inserted the axle into the driven worm gear and out through the remaining hole in the forward worm gear tower.
3. Pressed another "Arm, Worm Gear Driven.stl" onto the free end of the axle rotated 180 degrees from the first arm, then secured both arms to the axle using two "Bolt (M6 by 1 by 6mm).stl".
4. Repeated the previous three steps for the remaining axle, arms, driven worm gear and bolts in the rear worm gear tower.
5. As viewed from the right side of the assembly, rotated the rear driven worm gear assembly arm counter clockwise one tooth space, then inserted "Worm Gear.stl" into the base assembly between the center and rear propeller axle towers to secure the gear positions in place.
6. Rotated the worm gear to make certain the mechanism operated with ease.

To attach the dolphins, I performed the following steps:

1. Threaded four "Mount, Arm, Dolphin.stl" into the ends of the four worm gear driven arms.
2. Positioned one "Arm, Dolphin.stl" over two of the left side mounts then secured the dolphin in place using two "Axle, Arm, Dolphin.stl".
3. Repeated the previous step with the remaining dolphin arm and axles on the right side mounts.

To assemble and attach the propeller, I performed the following steps:

1. Glued "Axle, Propeller.stl" into the hub of "Propeller.stl".
2. Threaded two "Set Screw (M8 by 6).stl" into each of the three "Bushing, Axle, Propeller.stl".
3. Slid the propeller axle partially into the forward propeller axle tower, slid one bushing assembly onto the propeller axle with the bushing facing toward the forward propeller axle tower, slid a second bushing assembly onto the propeller axle with the bushing facing toward the center propeller axle tower, then slid the propeller axle through the worm gear and rear propeller axle tower.
4. Adjusted the position of each of the bushings on the propeller axle to engage each bushing in its respective propeller axle tower while making certain the propeller rotated with ease.
5. Secured the bushings to the axle by tightening the set screws.

To attach the wave panels and mount, I performed the following steps:

1. Attached one "Wave Mount.stl" to the outside of the rear propeller axle tower using two "Bolt (M8 by 1.25 by 8mm).stl".
2. Attached the remaining "Wave Mount.stl" to the inside of the forward propeller axle tower using two "Bolt (M8 by 1.25 by 8mm).stl"
3. Secured "Wave, Left.3mf" to the left side of the wave mounts using four "Bolt (M8 by 1.25 by 8mm).stl".
4. Repeated the previous step for "Wave, Right.3mf".
5. Attached "Mount.stl" to the front of the base assembly using two "Bolt (M8 by 1.25 by 8mm).stl".

For final assembly, I performed the following steps:

1. Secured the 16mm diameter ball bearing to the ball bearing cup in "Joiner.stl" using silicon adhesive.
2. Carefully slid the joiner into the mount tube making certain the joiner was fully inserted into the mount.

With assembly complete, I threaded the joiner assembly to the pole I've previously used for my whirligig designs using the M8 by 1.25 threaded rod and nut, then placed the model onto the joiner and let the wind do its work!

And that is how I 3D printed and assembled "Whirligig, Dolphins".

I hope you enjoyed it!