How to Print & Assemble The BOOSTER-S2

How to print the BOOSTER-S2

If you want to save this How-To instruction as a pdf file (and print it out later if needed), simply copy the URL of this page and paste it to https://www.printfriendly.com/ . Printfriendly will generate a printer-friendly pdf of the page with all the texts and images for you.

All of the STL files are really straight forward to print. All you need to do is load them into your slicer software (I use Cura), select your desirable settings (e.g. layer height, infill percentage, etc.) and slice the parts. I used 0.4mm nozzle and 0.2mm layer height to print large parts, and 0.1mm layer height to print small parts (e.g. Raptor Engines).

Please note: I already saved the STL for each part in the orientation I printed them on my FDM printer. Hence, when you load the STL in your slicer software, you don’t need to orientate them again, unless you want to try to print them in a different orientation.

Below are some tips.

  • All magnet holes can be printed without support regardless of their positions/orientations on the model. Please don’t generate support for these holes (unless you really need to). Otherwise, you may struggle to remove support inside the holes due to restricted access. The easiest way to stop Cura from generating support inside these magnet holes is to use support blocker to cover the holes.

  • All stiffeners (inside the CH4 and LOX Tank Sections) can be printed without support.

  • This Booster model is designed in such a way that allows you to assemble and disassemble the model into piece part level because almost every part is held together by magnets. However, if you prefer to glue everything (or some parts together), that’s also fine.

  • There is an STL in folder ‘STEP 01’ called ‘Booster-S2 Assy.stl’. If you load this file, you’ll see the fully assembled Booster-S2 model. This will help you understand where each and every part is fitted on the model.

  • This model is designed at 1:96 scale and I highly recommend you to print at this scale to achieve the highest quality. However, if you decided to print it at a different scale, please be aware that the magnets I selected for this model will no longer fit and you will have to glue the parts together.

How to assemble the BOOSTER-S2

So now you’ve got all your parts printed? Great! Let’s assemble the model!

I’ll take you through the assembly process step by step but before that, you need to purchase some items:

  • 5mm dia x 3mm thick N42 Neodymium magnets (LINK) | Qty: 96-off
  • 3mm dia x 2mm thick N42 Neodymium (LINK) | Qty: 35-off
  • Super glue (LINK) | Qty: 1 bottle

STEP 1: ‘Dry’ assemble the model

At this step, all I want you to do is try to stack all the parts together to get a good understanding of where they are located. Because there are a lot of magnets you need to fit during the assembly process, doing this first step will give you an idea of how to fit the magnets in each part correctly. Please use the ‘Booster-S2 Assy.stl’ and the photos below if required.

STEP 2: Assemble the Booster Aft Section

Parts required (refer to the photos below)

  • 1x Booster Aft_S2 (a)
  • 2x Location Pin_S2 (b)
  • 12x Magnets (5mm dia x 3mm thick) (highlighted in red)

Assembly process

  1. STEP 2a: Glue 6x magnets (5mm dia x 3mm thick) into their pockets at the top and side of the Booster Aft
  2. STEP 2b: Glue 6x magnets (5mm dia x 3mm thick) into their pockets at the bottom of the Booster Aft
  3. STEP 2c: Glue 2x Location Pins to 2 holes located at the top face of the Booster Aft

STEP 3: Assemble the Booster Thrust Puck

Parts required (refer to the photos below)

  • 1x Booster Aft_S2 from STEP 2 (a)
  • 1x Booster Thrust Puck_S2 (b)
  • 14x Magnets (5mm dia x 3mm thick) (highlighted in red)

Assembly process:

  1. STEP 3a: Glue 14x magnets (5mm dia x 3mm thick) into their pockets at the top and bottom sides of the Booster Thrust Puck
  2. STEP 3b: Glue the Booster Thrust Puck to the Booster Aft from STEP 2.
    IMPORTANT: Use the 2 cut-out slots on the sides of the Booster Thrust Puck for alignment with the Booster Aft. Note that the sizes of the slots are also different to aid orientation.

STEP 4: Assemble the Booster LOX Tank (Bottom) Section

Parts required (refer to the photos below)

  • 1x Booster LOX Tank (Bottom)_S2 (a)
  • 2x Location Pin_S2 (b)
  • 8x Magnets (5mm dia x 3mm thick) (highlighted in red)

Assembly process

  1. STEP 4a: Glue 8x magnets (5mm dia x 3mm thick) into their pockets at the top and bottom sides of the Booster LOX Tank (Bottom)
  2. STEP 4b: Glue 2x Location Pins to 2 holes located at the top face of the Booster LOX Tank (Bottom)

STEP 5: Assemble the Booster LOX Tank (Top) Section

Parts required (refer to the photos below)

  • 1x Booster LOX Tank (Top)_S2 (a)
  • 2x Location Pin_S2 (b)
  • 8x Magnets (5mm dia x 3mm thick) (highlighted in red)

Assembly process

  1. STEP 5a: Glue 8x magnets (5mm dia x 3mm thick) into their pockets at the top and bottom sides of the Booster LOX Tank (Top)
  2. STEP 5b: Glue 2x Location Pins to 2 holes located at the top face of the Booster LOX Tank (Top)

STEP 6: Assemble the Booster Common Dome Section

Parts required (refer to the photos below)

  • 1x Booster Common Dome_S2 (a)
  • 2x Location Pin_S2 (b)
  • 8x Magnets (5mm dia x 3mm thick) (highlighted in red)

Assembly process

  1. STEP 6a: Glue 8x magnets (5mm dia x 3mm thick) into their pockets at the top and bottom sides of the Booster Common Dome
  2. STEP 6b: Glue 2x Location Pins to 2 holes located at the top face of the Booster Common Dome

STEP 7: Assemble the Booster CH4 Tank Section

Parts required (refer to the photos below)

  • 1x Booster CH4 Tank_S2 (a)
  • 2x Location Pin_S2 (b)
  • 8x Magnets (5mm dia x 3mm thick) (highlighted in red)

Assembly process

  1. STEP 7a: Glue 8x magnets (5mm dia x 3mm thick) into their pockets at the top and bottom sides of the Booster CH4 Tank
  2. STEP 7b: Glue 2x Location Pins to 2 holes located at the top face of the Booster CH4 Tank

STEP 8: Assemble the Booster Interstage Section

Parts required (refer to the photos below)

  • 1x Booster Interstage_S2
  • 4x Magnets (5mm dia x 3mm thick) (highlighted in red)
  • 10x Magnets (3mm dia x 2mm thick) (highlighted in red)

Assembly process

  1. STEP 8a: Glue 6x magnets (3mm dia x 2mm thick) into their pockets at the top of the Booster Interstage
  2. STEP 8b: Glue 4x magnets (5mm dia x 3mm thick) into their pockets at the bottom of the Booster Interstage
  3. STEP 8c: Glue 4x magnets (3mm dia x 2mm thick) into their pockets at the side of the Booster Interstage

STEP 9: Assemble the Center Raptor Engines, Grid Fins, and COPV's

Parts required (refer to the photos below)

  • 13x Raptor Engine_S2 (a)
  • 13x Raptor Engine Shield_S2 (b)
  • 4x Grid Fin_S2 (c)
  • 10x COPV Tank_S2 (d)
  • 13x Magnet (5mm dia x 3mm thick) (highlighted in red)
  • 24x Magnet (3mm dia x 2mm thick) (highlighted in red)

Assembly process

  1. STEP 9a: Glue 1x magnet (5mm dia x 3mm thick) into its pocket at the top of the Raptor Engine Shield. Then glue 1x Raptor Engine to 1x Raptor Engine Shield. Repeat until you have 13x Raptor Engine Assemblies
  2. STEP 9b: Glue 1x magnet (3mm dia x 2mm thick) into its pocket on each Grid Fin
  3. STEP 9c: Glue 2x magnets (3mm dia x 2mm thick) into their pockets on each COPV Tank

STEP 10: Install Raptor Engines to Booster Aft Section

Parts required (refer to the photos below)

  • 1x Engine Skirt_S2 (a)
  • 20x Raptor Engine_S2 (b) (from STEP 9)
  • 2x Location Pin_S2 (c)
  • 13x Center Raptor Engine from STEP 9 (d)
  • 1x Booster Aft Section from STEP 3 (e)
  • 6x Magnet (5mm dia x 3mm thick) (highlighted in red)

Assembly process

  1. STEP 10a: Glue 6x magnet (5mm dia x 3mm thick) into their pockets at the top of the Engine Skirt
  2. STEP 10b: Glue 20x Raptor Engines to the bottom of the Engine Skirt
  3. STEP 10c: Glue 2x Location Pins to 2 holes located at the top face of the Engine Skirt
  4. STEP 10d: Install 13x Center Raptor Engines from STEP 9 to the Booster Aft Section
  5. STEP 10e: Install the Engine Skirt to the Booster Aft Section

STEP 11: Install CH4 plumbing to Booster Aft Section

Parts required (refer to the photos below)

  • 1x Booster CH4 Distribution Pipes (Top)_S2 (a)
  • 1x Booster CH4 Distribution Pipes (Mid)_S2 (b)
  • 1x Booster CH4 Distribution Pipes (Bottom)_S2 (c)
  • 1x Sub-assembly from STEP 10 (d)
  • 6x Magnets (5mm dia x 3mm thick) (highlighted in red)
  • 1x Magnet (3mm dia x 2mm thick) (highlighted in red)

Assembly process

  1. STEP 11a: Glue 2x magnets (5mm dia x 3mm thick) into their pockets on both ends of each CH4 Distribution Pipes and 1x magnets (3mm dia x 2mm thick) into the pocket on the side of the Booster CH4 Distribution Pipes (Top)
  2. STEP 11b: Install all the Booster CH4 Distribution Pipes to the Booster Aft Section. Ensure that all 10x pipes on the Booster CH4 Distribution Pipes (Bottom) go into the 10x holes located on the top face of the Booster Thrust Puck
  3. STEP 10c: Finally, rotate the Booster CH4 Distribution Pipes (Mid) & (Top) so that all the pipes are all equally spread out

STEP 12: Stack Booster LOX Tank Section

Parts required (refer to the photos below)

  • 2x Booster CH4 Downcomer Pipe_S2 (a)
  • 1x Booster CH4 Downcomer Joint_S2 (b)
  • 1x Booster LOX Tank (Top) Section from STEP 5 (c)
  • 1x Booster LOX Tank (Bottom) Section from STEP 4 (d)
  • 1x Booster Aft Section from STEP 11 (e)
  • 10x COPV Tank from STEP 9 (f)
  • 6x Magnet (5mm dia x 3mm thick) (highlighted in red)

Assembly process

  1. STEP 12a: Glue 2x magnets (5mm dia x 3mm thick) to both ends of Booster CH4 Downcomer Pipe (a) and Joint (b)
  2. STEP 12b: Assemble the CH4 Downcomer and insert it into the top of the Booster CH4 Distribution Pipes (Top)
  3. STEP 12b: Install the Booster LOX Tank (Bottom) Section to the Booster Aft Section
  4. STEP 12c: Install the COPV Tanks to the large chines on the Booster LOX Tank (Bottom) Section
  5. STEP 12c: Install the Booster LOX Tank (Top) Section to the Booster LOX Tank (Bottom) Section

STEP 13: Stack Booster Common Dome Section

Parts required (refer to the photos below)

  • 1x AVSB_S2 (a)
  • 1x Booster CH4 Downcomer (Top)_S2 (b)
  • 1x Booster Common Dome Section from STEP 6 (c)
  • 1x Sub-assembly from STEP 12 (d)
  • 3x Magnet (5mm dia x 3mm thick) (highlighted in red)

Assembly process

  1. STEP 13a: Glue 3x magnets (5mm dia x 3mm thick) to their pockets on the Booster CH4 Downcomer (Top) and AVSB (Anti-Vortex Slosh Baffles)
  2. STEP 13a: Install the Booster CH4 Downcomer (Top) and AVSB to the Booster Common Dome Section
  3. STEP 13b: Install the Booster Common Dome Section to the Sub-assembly from STEP 12

STEP 14: Stack Booster CH4 Tank Section

Parts required (refer to the photos below)

  • 1x Booster CH4 Tank Section from STEP 7 (a)
  • 1x Sub-assembly from STEP 13 (b)

Assembly process

  1. STEP 14: Install the Booster CH4 Tank Section to the Sub-assembly from STEP 13

STEP 15: Install Grid Fins & Forward Dome Cap

Parts required (refer to the photos below)

  • 2x Booster Forward Dome Cap_S2 (a)
  • 4x Booster Grid Fins from STEP 9 (b)
  • 1x Booster Interstage Section from STEP 8 (c)

Assembly process

  1. STEP 15a: Glue 2x halves of the Booster Forward Dome Cap together to make a full cap & press fit it into the Booster Interstage Section
  2. STEP 15b: Insert 4x Grid Fins into the holes around the Booster Interstage Section

STEP 16: Stack Booster Interstage Section

Parts required (refer to the photos below)

  • 1x Sub-Assembly from STEP 15 (a)
  • 1x Sub-Assembly from STEP 14 (b)

Assembly process

  1. STEP 16: Install the Booster Interstage Section from STEP 15 to Sub-Assembly from STEP 14

STEP 17: Complete BOOSTER-S2

Parts required (refer to the photos below)

  • 1x Sub-assembly from STEP 16

Assembly process

  1. STEP 17: Congratulations, you have fully built the BOOSTER-S2 model at this point!

STEP 18: Install the Booster Stand

Parts required (refer to the photos below)

  • 1x Booster Stand_S2 (a)
  • 1x Booster-S2 from STEP 17 (b)

Assembly process

  1. STEP 18a: Ensure that the Booster Stand is at the correct orientation (the front side of the Booster Stand is aligned with that of the Booster-S2)
  2. STEP 18b: Place the Booster-S2 on top of the Booster Stand
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