Easter Edition Flexi Rex 3D Print

For this project, I decided to 3D print the Easter Edition of Flexi Rex, a fun and flexible dinosaur figure with interlocking links that allow its body and tail to move. I found the model on Thingiverse and downloaded the CAD file created by Architekturpur.
Direct link to the file

Planning the Print

Before resizing the model, I measured the dimensions of the gumball capsule to ensure the print would fit inside. The capsule has a diameter of approximately 1.85 inches and a height of 2 inches, which converts to about 47 mm by 50.8 mm. To test the fit, I ran two initial test prints—scaling the model to both 50 mm and 48 mm in the Z-axis. After comparing the results, I found that the 48 mm version fit better inside the capsule, so I chose that size for my final prints. I used the Bambu printers for the test run, and the process went smoothly.

picture of 50 mm vs 48 mm test prints

Printing Process – Bambu Printer

For my first print, I used FDM printing with the Bambu printer. I prepared the file using the Bambu Studio slicer on one of the OEDK Maker Bar computers. To ensure a successful print, I first rotated the model horizontally so that as much of the surface area as possible would be in contact with the print bed, helping with bed adhesion. I scaled the Z-axis to 48 mm to match the capsule size. I then set the layer height to 0.15 mm and the infill density to 15%. Since the model includes bunny ears that extend upward and do not rest flat, I also enabled supports to help those sections print correctly.

Once everything was set, I sliced the file. To make efficient use of the available 3D printers and avoid taking up too many machines during busy times at OEDK, I combined my print with another classmate’s file. The test print took about 1.5 hours and produced a clean, detailed result.

After confirming the print quality and size, I printed two additional Flexi Rex models using white PLA filament.

picture of Bambu printer output

Printing Process – Prusa Printer

I also experimented with the Prusa printer, which was more challenging because I had no prior experience using it. Initially, I made the mistake of trying to print a file that had been sliced using the Bambu software, which caused the printer to malfunction and print spaghetti-like shapes. I quickly realized the issue and stopped the process.

Afterward, I re-sliced the file using the Prusa-specific software on one of the OEDK Maker Lab laptops and adjusted the settings accordingly. With those corrections in place, the Prusa printer produced a great result. Learning how to use both printers gave me valuable insight into the differences between them and how to troubleshoot problems across different systems.

picture of Prusa printer output

Once the prints were complete, I carefully removed the support structures, especially around the bunny ears and the interlocking joints. This part was delicate because the space was tight and I didn’t want to accidentally damage the model. I used tweezers to gently pull away the support material around the ears and moving parts to preserve the model’s flexibility.

picture of 5 gumball capsules with prints

picture of a clean workspace

I really enjoyed this assignment and am excited to have learned how to use both the Bambu and Prusa printers. While waiting for the prints to finish made me a bit anxious, and troubleshooting failed prints took some extra time, I found the process incredibly rewarding. I’m looking forward to experimenting more with 3D printing in future projects.

Cost Analysis

The material cost for this project was minimal. Since the models were small and used PLA filament, the actual filament used was negligible and could reasonably be rounded down to $0 for purposes of this estimate.

The primary cost of the project was time and labor. I spent approximately three hours on this project, which includes measuring and scaling the model, conducting test prints, preparing files for both Bambu and Prusa printers, and post-processing the prints. At a standard rate of $15 per hour, this amounts to a labor cost of $45.