How to print the FALCON 9 - S1
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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.
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At STEP 1, you’ll find 2 STL’s in the folder called FALCON 9 Assembly_01 and FALCON 9 Assembly_02 . If you load these files, you’ll see the fully assembled FALCON 9-S1 model. This will help you understand where each and every part is fitted on the model.
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At STEP 2, although there are separate STL files for the First Stage_Octaweb and the Merlin Engines in the folder. These two parts must be loaded together into the slicer to create a single part. The files are saved from the same coordinate so you don’t need to manually align them in your slicer, they should merge together automatically instead.
If you have a multi-colour printer, simply assign a different colour to each part.
To help gluing the magnets into this part easier, you can also print the Stand first (from STEP 9), then seat the First Stage_Octaweb/Merlin Engines part on the Stand to push the magnets in.
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There are two versions of the Landing Leg available for this model – Standard and Thicken
The default version included in STEP 03 (and STEP 10) folder is the Standard version. However, if you prefer to use the Thicken version instead, you can find this in STEP 99 (OPTIONAL PARTS) folder
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There are two versions of the MVAC Engine available for this model – Standard and Textured
The default version included in STEP 05 folder is the Standard version. There is another version of the MVAC Engine in STEP 99 (OPTIONAL PARTS) folder with the top section slightly modified so that it has the “Thermal blankets” texture-like to better represent the real hardware.
It’s up to you which version you prefer -
Every two main sections of the model are connected together using 9x magnets (5mm dia x 3mm thick), split into 3x stacks (3 magnets per stack).
Please note that the magnets in the middle of each stack also act as locating pins so they don’t sit flush to the top face of the section. These magnets should protrude approx. 1.5mm out.
See example below – the bottom and middle magnets of the 3x magnet stack are glued to the hole on the top face on the Interstage, and the top magnet is glue to the bottom face of the Second Stage. Once these two sections are stacked together, the middle magnet should sit right in the middle of the split line.
This magnet arrangement creates a strong bond between the two sections whilst prevent them from moving axially and radially away from each other.
(Click on the image to enlarge it)
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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.
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The FALCON 9-S1 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.
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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 originally selected for this model will no longer fit and you will have to glue the parts together.
How to assemble the FALCON 9 - S1
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:
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 2: Assemble the First Stage
Parts required (refer to the photos below)
- 1x First Stage_Octaweb/Merlin Engines (a)
- 1x First Stage_Fuel Tank (b)
- 1x First Stage_LOX Tank (c)
- 24x Magnets (5mm dia x 3mm thick) (highlighted in red)
- 4x Magnets (3mm dia x 2mm 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_Octaweb/Merlin Engines.
- STEP 2b: Glue 9x magnets (5mm dia x 3mm thick) into its pocket at the top (6x) and bottom (3x) of the First Stage_Fuel Tank. Glue 4x magnet (3mm dia x 2mm thick) into its pocket at the side of the First Stage_Fuel Tank.
- STEP 2c: Glue 9x magnets (5mm dia x 3mm thick) into its pocket at the top (6x) and bottom (3x) of the First Stage_LOX Tank.
STEP 3: Assemble the Landing Legs
Parts required (refer to the photos below)
- 4x Landing Leg (a)
- 4x Landing Leg Arm (a.k.a. Struts) (b)
- 4x Landing Legs Aerocover (c)
- 1x First Stage_Octaweb/Merlin Engines from STEP 1 (d)
- 1x First Stage_Fuel Tank from STEP 1 (e)
- 8x Landing Leg pins (f)
- 4x Magnets (5mm dia x 3mm thick) (highlighted in red)
- 12x Magnets (3mm dia x 2mm thick) (highlighted in red)
Assembly process:
- STEP 3a: Glue 1x 5mm dia x 3mm thick magnet and 1x 3mm dia x 2mm thick magnet into their pockets on each Landing Leg.
IMPORTANT: Please ensure the 3mm dia x 2mm thick magnet is seated properly in its pocket at the top of the Landing Leg!. Failing this means the Landing Leg may not be deployed correctly
- STEP 3b: Glue 2x magnets (3mm dia x 2mm thick) into their pockets on the Landing Leg Arm (a.k.a. Strut).
Please note: There isn’t any magnet hole at the small end of the Landing Leg Arm, you just need to carefully glue a magnet to it
- STEP 3c: Glue 4x Landing Leg Aerocovers to their pockets on the First Stage_Fuel Tank from STEP 1
- STEP 3d: Install the Landing Legs to the First Stage_Octaweb/Merlin Engines from STEP 1 using 8x Landing Leg pins
- STEP 3e: Install the First Stage_Fuel Tank to the First Stage_Octaweb/Merlin Engines and test to ensure that the Landing Legs are stowed and deployed properly.
STEP 4: Assemble the Interstage
Parts required (refer to the photos below)
- 1x Interstage (a)
- 4x Grid Fin_Folded (b)
- 4x Grid Fin_Extended (c)
- 9x Magnets (5mm dia x 3mm thick) (highlighted in red)
- 12x Magnets (3mm dia x 2mm thick) (highlighted in red)
Assembly process
- STEP 4a: Glue 9x magnets (5mm dia x 3mm thick) into its pocket at the top (6x) and bottom (3x) of the Interstage. Glue 4x magnet (3mm dia x 2mm thick) into its pocket at the side of the Interstage.
- STEP 4b: Glue 1x magnet (3mm dia x 2mm thick) to each Grid Fin – see pic below for reference.
Please note: There are 2x sets of the Grid Fins (Folded & Extended). There aren’t any magnet holes on the Grid Fins, you just need to carefully glue a magnet to it
- STEP 4c: Assemble the Grid Fins to the Interstage and ensure that they can be rotated smoothly
STEP 5: Assemble the Second Stage
Parts required (refer to the photos below)
- 1x Second Stage (a)
- 1x MVAC Engine (b)
- 8x Magnets (5mm dia x 3mm thick) (highlighted in red)
Assembly process
- STEP 5a: Glue 7x magnets (5mm dia x 3mm thick) into their pockets at the top (3x) and bottom (4x) of the Second Stage
- STEP 5b: Glue 1x magnet (5mm dia x 3mm thick) into its pocket at the top of the MVAC Engine
- STEP 5c: Assemble the MVAC Engine to the Second Stage
STEP 6: Assemble the Payload Fairings
Parts required (refer to the photos below)
- 2x Payload Fairing (a)
- 1x Payload Adaptor (b)
- 4x Magnets (5mm dia x 3mm thick) (highlighted in red)
- 8x Magnets (3mm dia x 2mm thick) (highlighted in red)
Assembly process
- STEP 6a: Glue 4x magnets (3mm dia x 2mm thick) into their pockets on each Payload Fairing
- STEP 6b: Glue 4x magnets (5mm dia x 4mm thick) into their pockets on the top and bottom of the Payload Adaptor
- STEP 6c: Assemble both halves of the Payload Fairings to the Payload Adaptor
STEP 7: Assemble the Raceways
Parts required (refer to the photos below)
- 1x Small Raceway_01 (a)
- 1x Small Raceway_02 (b)
- 1x Small Raceway_03 (c)
- 1x Large Raceway_01 (d)
- 1x Large Raceway_02 (e)
- 1x Large Raceway_03 (f)
- 1x First Stage Sub-assembly from STEP 3
- 1x Interstage Sub-assembly from STEP 4
Assembly process
- STEP 7a: Glue all the Small Raceway segments to the FRONT side of the First Stage and Interstage sub-assemblies
- STEP 7b: Glue all the Large Raceway segments to the REAR side of the First Stage and Interstage sub-assemblies
Please note: The Small and Large Raceway_03 may look similar but they are not identical! The Small Raceway_03 has a rounder base compared to the Large one. Therefore, please do not mix them up as they are not interchangeable.
STEP 8: Assemble the FALCON 9
Parts required (refer to the photos below)
- 1x First Stage Sub-assembly from STEP 3
- 1x Interstage Sub-assembly from STEP 4
- 1x Second Stage Sub-assembly from STEP 5
- 1x Payload Fairings Sub-assembly from STEP 6
Assembly process
- STEP 8: Stack all the Sub-assemblies together!
STEP 9: Assemble the Stand
Parts required (refer to the photos below)
- 1x FALCON 9 from STEP 8 (a)
- 1x FALCON 9_Stand (b)
- 9x Stand rods (2mm Dia x 45mm L) (c)
Assembly process
- STEP 9a: Removed all 4x Landing Leg Arms and store them inside the First Stage_Fuel Tank
- STEP 9b: Place the FALCON 9 on its Stand.
Please note: To further increase the stability of the model when the Stand is used, cut 9x 2mm dia rods to the correct length (45mm) and install them into the Stand first before seating the FALCON 9 on top
Congratulations, you have fully built the FALCON 9-S1 model at this point!
