How to print the FALCON HEAVY - 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 a number of STL’s in the STEP 01 (DO NOT PRINT) folder. If you load these files, you’ll see the fully assembled FALCON HEAVY-S1 model. This will help you understand where each and every part is fitted on the model.
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At STEP 2 and STEP 9, 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 15), 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 HEAVY-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 HEAVY - 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:
- 5mm dia x 3mm thick N42 Neodymium magnets (LINK) | Qty: 135-off
- 3mm dia x 2mm thick N42 Neodymium (LINK) | Qty: 104-off
- 3mm dia x 20mm L Dowel Pin (LINK) | Qty: 6-off (I highly recommend using plain steel rather than stainless steel pins for this model due to its magnetic properties)
- Brass Solid Round Rod 2mm Diameter 100mm Length (LINK) | Qty: 14-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 2: Assemble the Centre Core_First Stage
Parts required (refer to the photos below)
- 1x First Stage (Centre)_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)
- 10x 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. Then glue 6x magnets (3mm dia x 2mm thick) into the side pockets (3 per each side)
IMPORTANT: Ensure all the 3mm dia x 2mm thick magnets are pushed all the way into the side pockets (see pic below). Failing this means the Side Cores can’t be attached to the Centre Core properly later on
- 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. Then 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 Centre Core_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 (Centre)_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 (Centre)_Octaweb/Merlin Engines from STEP 1 using 8x Landing Leg pins
- STEP 3e: Install the First Stage_Fuel Tank to the First Stage (Centre)_Octaweb/Merlin Engines and test to ensure that the Landing Legs are stowed and deployed properly.
STEP 4: Assemble the Centre Core_Interstage
Parts required (refer to the photos below)
- 1x Interstage (a)
- 4x Grid Fin_Folded (b)
- 4x Grid Fin_Extended (c)
- 15x Magnets (5mm dia x 3mm thick) (highlighted in red)
- 12x Magnets (3mm dia x 2mm thick) (highlighted in red)
Assembly process
- STEP 4a: Glue 15x magnets (5mm dia x 3mm thick) into its pocket at the top (6x), bottom (3x), and side (6x) of the Interstage. Then glue 4x magnet (3mm dia x 2mm thick) into its pocket at the side of the Interstage.
IMPORTANT: Ensure all the 3mm dia x 2mm thick magnets are pushed all the way into the side pockets. Failing this means the Grid Fins can’t be attached to the Interstage properly
- 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 Centre Core_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 Centre Core_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 Centre Core_Raceways & Separation Pusher (Stowed)
Parts required (refer to the photos below)
- 1x Small Raceway_01 (a)
- 1x Small Raceway_02 (b)
- 1x Front Separation Pusher (Stowed) (c)
- 1x Large Raceway_01 (d)
- 1x Large Raceway_02 (e)
- 1x Rear Separation Pusher (Stowed) (f)
- 1x First Stage Sub-assembly from STEP 3
- 1x Interstage Sub-assembly from STEP 4
- 2x Magnets (5mm dia x 3mm thick) (highlighted in red)
Assembly process
- STEP 7a: Glue 1x magnet (5mm dia x 3mm thick) into its pocket on each of the Separation Pusher (Stowed)
Please note: The Front and Rear Separation Pusher (Stowed) may look similar but they are not identical! The Front Separation Pusher (Stowed) has a rounder base compared to the Rear one. Therefore, please do not mix them up as they are not interchangeable.
- STEP 7b: Glue the Small Raceway 01 & 02 segments to the FRONT side of the Centre Core_First Stage sub-assemblies. Then install the Front Separation Pusher (Stowed) to the Centre Core_Interstage.
- STEP 7c: Glue the Large Raceway 01 & 02 segments to the REAR side of the Centre Core_First Stage sub-assemblies. Then install the Rear Separation Pusher (Stowed) to the Centre Core_Interstage.
STEP 8: Assemble the Centre Core
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 Side Core_First Stage
Parts required (refer to the photos below)
- 2x First Stage (Side)_Octaweb/Merlin Engines (a)
- 2x First Stage_Fuel Tank (b)
- 2x First Stage_LOX Tank (c)
- 48x Magnets (5mm dia x 3mm thick) (highlighted in red)
- 14x Magnets (3mm dia x 2mm thick) (highlighted in red)
Assembly process
- STEP 9a: Glue 6x magnets (5mm dia x 3mm thick) into its pocket at the top of the First Stage (Side)_Octaweb/Merlin Engines. Then glue 3x magnets (3mm dia x 2mm thick) into the side pockets
IMPORTANT: Ensure all the 3mm dia x 2mm thick magnets are pushed all the way into the side pockets (see pic below). Failing this means the Side Cores can’t be attached to the Centre Core properly later on
- STEP 9b: Glue 9x magnets (5mm dia x 3mm thick) into its pocket at the top (6x) and bottom (3x) of the First Stage_Fuel Tank. Then glue 4x magnet (3mm dia x 2mm thick) into its pocket at the side of the First Stage_Fuel Tank.
- STEP 9c: 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 9d: Repeat the STEPs above for the 2nd Side Core
Please note: Both Side Cores are identical!
STEP 10: Assemble the Side Core_Landing Legs
Parts required (refer to the photos below)
- 8x Landing Leg (a)
- 8x Landing Leg Arm (a.k.a. Struts) (b)
- 8x Landing Legs Aerocover (c)
- 2x First Stage (Side)_Octaweb/Merlin Engines from STEP 9 (d)
- 2x First Stage_Fuel Tank from STEP 9 (e)
- 16x Landing Leg pins (f)
- 8x Magnets (5mm dia x 3mm thick) (highlighted in red)
- 24x Magnets (3mm dia x 2mm thick) (highlighted in red)
Assembly process:
- STEP 10a: 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 10b: 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 10c: Glue 4x Landing Leg Aerocovers to their pockets on the First Stage_Fuel Tank from STEP 9
- STEP 10d: Install the Landing Legs to the First Stage (Side)_Octaweb/Merlin Engines from STEP 9 using 8x Landing Leg pins
- STEP 10e: Install the First Stage_Fuel Tank to the First Stage (Side)_Octaweb/Merlin Engines and test to ensure that the Landing Legs are stowed and deployed properly.
- STEP 10f: Repeat the STEPs above for the 2nd Side Core
STEP 11: Assemble the Side Core_Nose Cone
Parts required (refer to the photos below)
- 2x Side Core_Nose Cone (a)
- 8x Grid Fin_Folded (b)
- 8x Grid Fin_Extended (c)
- 12x Magnets (5mm dia x 3mm thick) (highlighted in red)
- 24x Magnets (3mm dia x 2mm thick) (highlighted in red)
Assembly process
- STEP 11a: Glue 6x magnets (5mm dia x 3mm thick) into its pocket at the bottom (3x), and side (3x) of the Side Core_Nose Cone. Then glue 4x magnet (3mm dia x 2mm thick) into its pocket at the side of the Side Core_Nose Cone.
IMPORTANT: Ensure all magnets are pushed all the way into their pockets.
- STEP 11b: 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 11c: Assemble the Grid Fins to the Side Core_Nose Cone and ensure that they can be rotated smoothly
- STEP 11d: Repeat the STEPs above for the 2nd Side Core
STEP 12: Assemble the Side Core_Raceways
Parts required (refer to the photos below)
- 2x Small Raceway_01 (a)
- 2x Small Raceway_02 (b)
- 2x Small Raceway_03 (c)
- 2x Large Raceway_01 (d)
- 2x Large Raceway_02 (e)
- 2x Large Raceway_03 (f)
- 2x Side Core_First Stage Sub-assembly from STEP 10
- 2x Side Core_Nose Cone Sub-assembly from STEP 11
- 4x Magnets (5mm dia x 3mm thick) (highlighted in red)
Assembly process
- STEP 12a: Glue 1x magnet (5mm dia x 3mm thick) into its pocket on the Small Raceway_03 and Large Raceway_03
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 12b: Glue the Small Raceway 01 & 02 segments to the FRONT side of the Side Core_First Stage sub-assemblies. Then install the Small Raceway_03 to the Side Core_Nose Cone.
- STEP 7c: Glue the Large Raceway 01 & 02 segments to the REAR side of the Side Core_First Stage sub-assemblies. Then install the Large Raceway_03 to the Side Core_Nose Cone
- STEP 7d: Repeat the STEPs above for the 2nd Side Core
At this Stage, you have now fully assembled the Centre Core, and the two Side Cores! You can display them individually just like that, OR continue to the next STEPs to join them together!
STEP 13: Pre-Final Assembly
Parts required (refer to the photos below)
- 1x Fully assembled Centre Core from STEP 8 (a)
- 2x Fully assembled Side Core from STEP 12 (b)
Assembly process
- STEP 13a: Place all 3 Cores next to each other (with their correct orientations – see pictures below) on a flat surface. Remove the Front Separation Pusher (Stowed) from the Centre Core, a Small Raceway_03, and a Large Raceway_03 from each of the Side Core
- STEP 13b: Turn all 3 Cores up side down, then remove the Rear Separation Pusher (Stowed) from the Centre Core, the remaining Small Raceway_03, and the Large Raceway_03 from each of the Side Core
STEP 14: Final Assembly
Parts required (refer to the photos below)
- 1x Front Separation Pusher (Deployed) (a)
- 1x Rear Separation Pusher (Deployed) (b)
- 2x Bottom Separation Connector (c)
- 6x Dowel Pins (3mm Dia x 20mm L) (d)
- 1x Centre Core from STEP 13 (e)
- 2x Side Core from STEP 13 (f)
- 6x Magnets (5mm dia x 3mm thick) (highlighted in red)
Assembly process
- STEP 14a: Glue 3x magnets (5mm dia x 3mm thick) into its pockets on the Front Separation Pusher (Deployed).
- STEP 14b: Glue 3x magnets (5mm dia x 3mm thick) into its pockets on the Rear Separation Pusher (Deployed).
- STEP 14c: Connect the bottom of the 3x Cores together (via their Octowebs) using 6x Dowel Pins (3 each side) and 2x Bottom Separation Connector (1 each side)
- STEP 14d: Connect the top of the 3x Cores together using the Front & Rear Separation Pusher (Deployed)
Please note: The Front & Rear Separation Pusher (Deployed) may look similar but they are not identical! The Front Separation Pusher (Deployed) has a rounder base compared to the Rear one. Therefore, please do not mix them up as they are not interchangeable.
STEP 15: Assemble the Stand
Parts required (refer to the photos below)
- 1x FALCON HEAVY from STEP 14 (a)
- 1x FALCON HEAVY_Stand (b)
- 27x Stand rods (2mm Dia x 45mm L) (c)
Assembly process
- STEP 15a: Removed all the Landing Leg Arms and store them inside the First Stage_Fuel Tank of the Centre Core and Side Cores
- STEP 15b: Place the FALCON HEAVY on its Stand.
Please note: To further increase the stability of the model when the Stand is used, cut 27x 2mm dia rods to the correct length (45mm) and install them into the Stand first before seating the FALCON HEAVY on top
Congratulations, you have fully built the FALCON HEAVY-S1 model at this point!
