How to print the FALCON 1 - M1

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The STL package of this model includes an “All-In-One” Print Profile created for Bambu Lab X1 and P1 Series 3D printers. If you intend to use any of those printers to print the model, follow this instruction to print all parts: How to use Bambu Studio’s All-In-One Print Profile

If you don’t have access to any Bambu Lab X1 and P1 Series 3D printers. All of the STL files are really straight forward to print. All you need to do is load them into your slicer software, select your desirable settings (e.g. layer height, infill percentage, etc.) and slice the parts. All part of this model can be printed with a standard 0.4mm Nozzle.

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.

At STEP 1, you’ll find an STL in the folder called FALCON 1 Assembly. If you load this file, you’ll see the fully assembled FALCON 1-M1 model. This will help you understand where each and every part is fitted on the model.
At STEP 5, there are two versions of the Payload Fairing (1-piece and 2-piece). You only need to print one
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 FALCON 1-M1 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, you can use the Locating Pins (in STEP 99 – OPTIONAL PARTS folder) instead.
This model is designed at 1:48 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 originally selected for this model will no longer fit and you will have to glue the parts together.

If you want to print this model at 1:96 scale, simply scale down all parts to 50% in your slicer. At this scale, you MUST use a 0.2mm Nozzle to print the model in order to retain the details

How to assemble the FALCON 1 - M1

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: 25-off
3mm dia x 2mm thick N42 Neodymium (LINK) | Qty: 6-off
Brass Solid Round Rod 2mm Diameter 100mm Length (LINK) | Qty: 1-off (This part is optional but I highly recommend)
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 STL files in STEP 01 folder and the photos below if required.

STEP 1

STEP 2: Assemble the 1st Stage

Parts required (refer to the photos below)

1x 1st Stage (a)
8x Magnets (5mm dia x 3mm thick) (highlighted in red)

Assembly process

STEP 2a: Glue 6x magnets (5mm dia x 3mm thick) into its pocket at the top of the First Stage.
STEP 2b: Glue 2x magnets (5mm dia x 3mm thick) into its pocket at the bottom of the First Stage

STEP 2a

STEP 2b

STEP 3: Assemble the Interstage

Parts required (refer to the photos below)

1x Interstage (a)
6x Magnets (5mm dia x 3mm thick) (highlighted in red)

Assembly process:

STEP 3a: Glue 3x magnets (5mm dia x 3mm thick) into its pocket near the top of the Interstage.
STEP 3b: Glue 3x magnets (5mm dia x 3mm thick) into its pocket at the bottom of the Interstage.

Please note: ensure that the 3x magnets at the bottom are pushed all the way in. There should be a 1.5mm gap between the bottom of these magnets, and the bottom face of the Interstage

STEP 3a

STEP 3b

STEP 4: Assemble the 2nd Stage

Parts required (refer to the photos below)

1x 2nd Stage (Bottom) (a)
1x 2nd Stage (Top) (b)
3x Locating Pin (Short) (c)
8x Magnets (5mm dia x 3mm thick) (highlighted in red)
2x Magnets (3mm dia x 2mm thick) (highlighted in red)

Assembly process

STEP 4a: Glue 7x magnets (5mm dia x 3mm thick) into its pocket at the bottom of the 2nd Stage (Bottom).
STEP 4b: Glue 1x magnet (5mm dia x 2mm thick), and 2x magnets (3mm dia x 2mm thick) into its pocket at the top of the 2nd Stage (Top).
STEP 4c: Glue the Top and Bottom of the 2nd Stage together (use 3x Locating Pins from STEP 99 OPTIONAL folder if required)

STEP 4a

STEP 4b

STEP 4c

STEP 5: Assemble the Payload Fairing

Parts required (refer to the photos below)

1x Payload Fairing (1st half) (a)
1x Payload Fairing (2nd half) (b)
4x Magnets (3mm dia x 2mm thick) (highlighted in red)

Assembly process

STEP 5a: Glue 2x magnets (3mm dia x 2mm thick) into their pockets at the top and bottom of one Fairing
STEP 5b: Repeat the same with the other Fairing

STEP 5a

STEP 5b

STEP 6: Assemble the Engines

Parts required (refer to the photos below)

1x Merlin 1C Engine (a)
1x 2nd Stage Engine (b)
3x Magnets (5mm dia x 3mm thick) (highlighted in red)

Assembly process

STEP 6a: Glue 2x magnets (5mm dia x 3mm thick) into their pockets at the top of the Merlin 1C Engine
STEP 6b: Glue 1x magnet (5mm dia x 3mm thick) into its pocket at the top of the 2nd Stage Engine