How to print the PERSEVERANCE

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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.

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.

There are a number of STL’s in folder ‘STEP 01 (DO NOT PRINT)’.
If you load these files in your slicer, you’ll see the fully assembled PERSEVERANCE model, as well as all the main sub-assemblies. This will help you understand where each and every part is fitted on the model. Please note that these files are for guidance only, hence do not try to print them
This model uses strong Neodymium magnets at most of the joints, not only to keep the parts together, but also to ensure all the joints move as design intent, so that some of the main mechanism such as the “rocker-bogie” suspension system, robotic arm, etc. are fully functional.
If you do use Neodymium magnets for your model, please ensure that they are at least N42 grade (even better if you can source them in N52 grade) for their strong pull force.

However, if you prefer to glue everything (or some parts together) rather than using magnets, that’s also fine. But please be aware that you may lose some of the functionalities.
This model requires a multi-colour printer as there are a number of parts that has more than one colour. If you use the provided X1C profile, all of these parts have been painted with the correct colour scheme. You only need to load the right colour into your printer and slice them.

If you don’t have a multi-colour printer, you will have to print the entire part in one single colour, and paint it later
There are many parts of the “Rocker-Bogie” suspension system of the PERSEVERANCE that look very similar to each other. This is because these parts have both Left, and Right Handed versions. They might look similar, but definitely NOT identical, and NOT interchangeable, so please don’t mix them up during the assembly process.
All parts of the PERSEVERANCE model can be printed with a standard 0.4mm Nozzle. However, there are two parts that MUST be printed with a smaller 0.2mm Nozzle:

Mars 2020 plate
Perseverance plate

This is because of the small text on these parts. If you print them with a 0.4mm Nozzle, the text won’t be readable.
Many other small parts of the PERSEVERANCE may also be beneficial from printing with a 0.2mm Nozzle to achieve better definition of their small features, but this is optional and it’s entirely up to you
Unlike the PERSEVERANCE, all parts of the INGENUITY model SHOULD be printed with a smaller 0.2mm Nozzle!

Otherwise, you won’t achieve the level of details this model can offer.
This model is designed at 1:12 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 PERSEVERANCE

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:

10mm dia x 2mm thick N42 Neodymium (LINK) | Qty: 35-off
5mm dia x 3mm thick N42 Neodymium magnets (LINK) | Qty: 15-off
M3 x 10mm Hex Socket Cap Screw (LINK) | Qty: 12-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 files from the ‘STEP 01 (DO NOT PRINT)‘ folder, and the photos below if required.

STEP 1

STEP 2-1: Assemble the Main Body (LEFT Side)

Parts required (refer to the photos below)

1x Main Body (a)
1x Body Part_01 (b)
1x Body Part_02 (c)
1x Body Part_03 (d)
1x Body Part_04 (e)
1x Body Part_05 (f)
1x Body Part_16 (g)
1x Down Look Camera (h)
1x Magnet (10mm dia x 2mm thick) (highlighted in red)

Assembly process

STEP 2-1a: Glue 1x magnet (10mm dia x 2mm thick) into the pocket at the left side of the Main Body

IMPORTANT: Push the magnet in as far as you can. It should sit approx. 1mm deep from the top of the hole.
STEP 2-1b: Glue all the Body parts mentioned above to the left side of the Main Body.

STEP 2-1a

STEP 2-1b

STEP 2-2: Assemble the Main Body (RIGHT Side)

Parts required (refer to the photos below)

1x Main Body from STEP 2-1 above (a)
1x Body Part_06 (b)
1x Body Part_07 (c)
1x Body Part_17 (d)
1x Magnet (10mm dia x 2mm thick) (highlighted in red)

Assembly process:

STEP 2-2a: Glue 1x magnet (10mm dia x 2mm thick) into the pocket at the right side of the Main Body

IMPORTANT: Push the magnet in as far as you can. It should sit approx. 1mm deep from the top of the hole.
STEP 2-2b: Glue all the Body parts mentioned above to the right side of the Main Body.

STEP 2-2a

STEP 2-2b

STEP 2-3: Assemble the Main Body (FRONT Side)

Parts required (refer to the photos below)

1x Main Body from STEP 2-2 above (a)
1x Body Part_08 (b)
1x Calibration Target (c)
1x Hazcams_Front (d)
2x MEDA Front Sensor (e)
1x Sample Handling Wheel (f)

Assembly process

STEP 2-3a: Glue all the Body parts mentioned above to the right side of the Main Body

STEP 2-3a

STEP 2-4: Assemble the Main Body (REAR Side)

Parts required (refer to the photos below)

1x Main Body from STEP 2-3 above (a)
1x Body Part_18 (b)
1x Body Part_19 (b)
2x Hazcams_Rear (d)

Assembly process

STEP 2-4a: Glue all the Body parts mentioned above to the right side of the Main Body.

STEP 2-4a

STEP 2-5: Assemble the Main Body (TOP Side)

Parts required (refer to the photos below)

1x Main Body from STEP 2-4 above (a)
1x Body Part_09 (b)
1x Body Part_09 Pin (c)
1x Body Part_10 (d)
3x Body Part_11 (e)
1x Body Part_12 (f)
1x Body Part_13 (g)
1x Body Part_14 (h)
1x Body Part_15 (i)
1x Body Part_20 (j)
1x Bridge (k)
1x 11 Million Names Placard (l)
1x Antenna_High Gain (m)
1x Antenna_Low Gain (n)
1x Antenna_UHF (o)
1x Mastcam-Z Calibration Targets (p)
1x MEDA (q)
1x Magnet (10mm dia x 2mm thick) (highlighted in red)
1x Magnet (5mm dia x 3mm thick) (highlighted in red)

Assembly process

STEP 2-5a: Glue 1x magnet (10mm dia x 2mm thick), and 1x magnet (5mm dia x 3mm thick) into their pockets on the top side of the Main Body

IMPORTANT: Push the magnets in as far as you can.
STEP 2-5b: Glue the Body parts g, h, k, l mentioned above to the top side of the Main Body.
STEP 2-5c: Glue the Body parts d, n, o mentioned above to the top side of the Main Body.
STEP 2-5d: Glue the Body parts b, c, p, q mentioned above to the top side of the Main Body.
STEP 2-5e: Glue the Body parts e (x3), j mentioned above to the top side of the Main Body.
STEP 2-5f: Glue the Body parts h, i, m mentioned above to the top side of the Main Body.

STEP 3: Assemble the Radioisotope Power Module

Parts required (refer to the photos below)

1x Main Body from STEP 2 above (a)
1x Radioisotope Power Source Mount (b)
1x Radioisotope Power Source Core (c)
1x Radioisotope Power Source Casing (d)
3x Radioisotope Power Source Locating Pin (e)
1x Radioisotope Power Source Bracing (f)
1x Radioisotope Power Source Cables_Top LH (g)
1x Radioisotope Power Source Cables_Mid LH (h)
1x Radioisotope Power Source Cables_Bottom LH (i)
1x Radioisotope Power Source Cables_Top RH (j)
1x Radioisotope Power Source Cables_Mid RH (k)
1x Radioisotope Power Source Cables_Bottom RH (l)
2x Radioisotope Power Source Linkage (m)
1x RIMFAX (n)
4x Magnet (5mm dia x 3mm thick) (highlighted in red)

Assembly process

STEP 3a: Glue 2x magnets (5mm dia x 3mm thick) into their pockets on the Radioisotope Power Source Mount. Please note that these magnets do protrude out slightly from the magnet hole (approx. 1mm)
STEP 3b: Glue the Radioisotope Power Source Mount and Core together using 3x Locating Pins. Ensure that the parts are correctly aligned before gluing
STEP 3c: Glue the Cables to both sides of the Radioisotope Power Source Casing, and also the Bracing to the rear
STEP 3d: Glue the Radioisotope Power Source Mount/Core sub-assembly above to the Main Body from STEP 2
STEP 3e: Glue the Radioisotope Power Source Casing sub-assembly above to the Main Body from STEP 2

IMPORTANT: Ensure the Radioisotope Power Source Casing is correctly aligned to the Main Body before gluing – use the aligning features near the top on both sides of the Casing. These features should slide into their corresponding slots on the Main Body
STEP 3f: Glue the Linkages to the rear of the Main Body – note that the other end of the linkage should sit correctly between the brackets on both sides of the Radioisotope Power Source Casing
STEP 3g: Glue 2x magnets (5mm dia x 3mm thick) into their pockets on the RIMFAX.
STEP 3h: Assemble the RIMFAX to the bottom of the Radioisotope Power Source Mount

Please note: The RIMFAX is magnetically attached to the Radioisotope Power Module so it can be detachable if needed. However, if you want to permanently glue this part rather using magnets, simply print 2x more Locating Pins from STEP 3b and use them to help align the RIMFAX for gluing

STEP 4-1: Assemble the Suspension System (LEFT Side)

Parts required (refer to the photos below)

1x Front Wheel Steering Bracket_LH (a)
1x Front Wheel Steering Motor_LH (b)
1x Rocker Front Shaft_LH (c)
1x Rocker Joint_LH (d)
1x Rocker Rear Shaft_LH (e)
1x Bogie Joint 1_LH (f)
1x Bogie Joint 2_LH (g)
1x Bogie Front Shaft_LH (h)
1x Bogie Rear Shaft_LH (i)
1x Rear Wheel Steering Motor_LH (j)
1x Rear Wheel Steering Bracket_LH (k)
6x Magnets (10mm dia x 2mm thick) (highlighted in red)
2x Magnets (5mm dia x 3mm thick) (highlighted in red)

Assembly process

STEP 4-1a: Glue 1x magnet each (10mm dia x 2mm thick) into the pocket at the top of the Front & Rear Wheel Steering Brackets
STEP 4-1b: Glue 1x magnet each (10mm dia x 2mm thick) into the pocket at the bottom of the Front & Rear Wheel Steering Motors
STEP 4-1c: Glue 2x magnets (10mm dia x 2mm thick) into the pocket at the side of the Rocker Joint. Please note that the outer magnet does protrude out slightly from the magnet hole (approx. 1mm)
STEP 4-1d: Glue 1x magnet each (5mm dia x 3mm thick) into the pocket at bottom of the the Bogie Joint 1 & top of the Bogie Joint 2
STEP 4-1e: Assemble the Left Suspension by gluing the shafts to the corresponding joints.

IMPORTANT: Magnets MUST be used as per instructions above to ensure all the joints move as design intent, so that the “rocker-bogie” suspension system is fully functional. Please DO NOT glue parts together where they are intended to magnetically attach to each other

STEP 4-2: Assemble the Suspension System (RIGHT Side)

Parts required (refer to the photos below)

1x Front Wheel Steering Bracket_RH
1x Front Wheel Steering Motor_RH
1x Rocker Front Shaft_RH
1x Rocker Joint_RH
1x Rocker Rear Shaft_RH
1x Bogie Joint 1_RH
1x Bogie Joint 2_RH
1x Bogie Front Shaft_RH
1x Bogie Rear Shaft_RH
1x Rear Wheel Steering Motor_RH
1x Rear Wheel Steering Bracket_RH
6x Magnets (10mm dia x 2mm thick) (highlighted in red)
2x Magnets (5mm dia x 3mm thick) (highlighted in red)

Assembly process

STEP 4-2: Follow the exact same instructions from STEP 4-1a to 4-1e above to assemble the Right Suspension

STEP 4-2

STEP 4-3: Assemble the Differential Bar

Parts required (refer to the photos below)

1x Main Body from STEP 3 (a)
1x LH Suspension from STEP 4-1 (b)
1x RH Suspension from STEP 4-2 (c)
1x Differential Bar (d)
1x Differential Bar Damper_01 (e)
1x Differential Bar Damper_02 (f)
2x Differential Bar Linkage (g)
4x Differential Bar Linkage Pin (h)
2x Magnet (10mm dia x 2mm thick) (highlighted in red)
1x Magnet (5mm dia x 3mm thick) (highlighted in red)

Assembly process

STEP 4-3a: Glue 2x magnets (10mm dia x 2mm thick) into the pocket at the bottom of the Differential Bar. Please note that the outer magnet does protrude out slightly from the magnet hole (approx. 1mm)
STEP 4-3b: Glue 1x magnet (5mm dia x 3mm thick) into the pocket at the bottom of the Differential Bar Damper_02. Please note that the magnet does protrude out slightly from the magnet hole (approx. 1.5mm)
STEP 4-3c: Glue the Differential Bar Damper_01 to the Main Body, and then install the Damper_02 to the left of the Damper_01.

IMPORTANT: DO NOT glue the Damper_02 to the Main Body. This part should only be held in place by magnet.
STEP 4-3d: Install the Differential Bar to the Main Body. This part should only be held in place by magnet and should be able to rotate around the centre magnet.
STEP 4-3e: Install the Suspension LH & RH to the sides of the Main Body. Again, both of these parts should only be held in place by magnets and should be able to rotate around their centre magnets.
STEP 4-3f: Connect the ends of the Differential Bar to the Suspension main joints using the Linkages (2x) and Pins (4x)

STEP 4-4: Assemble the Wheels

Parts required (refer to the photos below)

1x Main Body from STEP 4-3 (a)
3x Wheel_LH (b)
3x Wheel_RH (c)
6x Wheel Spokes (e)
12x M3x10 Screw (f)

Assembly process

STEP 4-4a: Glue one Wheel Spoke to each Wheel.

IMPORTANT: Ensure the Wheel Spoke in inserted to the correct side of each Wheel before gluing. See the section-view pic of the Wheel below for clarity
STEP 4-4b: Install each Wheel to the Suspension using one M3x10mm Socket Cap Hex Screw
STEP 4-4c: Repeat the process until all 6x Wheels are installed to the Main Body

STEP 4-4a

STEP 4-4b

STEP 4-4c

STEP 5: Assemble the MAST

Parts required (refer to the photos below)

1x Main Body from STEP 4 (a)
1x MAST Base_Front (b)
1x MAST Base_Mid (c)
1x MAST Base_Rear (d)
1x MAST Lower Shaft (e)
1x MAST Upper Shaft (f)
1x MAST Head (g)
1x MAST Head Service Loop _EL (h)
4x Magnet (10mm dia x 2mm thick) (highlighted in red)
5x Magnet (5mm dia x 3mm thick) (highlighted in red)

Assembly process

STEP 5a: Glue 1x magnet each (10mm dia x 2mm thick) into the pocket at the MAST Base_Front & Rear
STEP 5b: Glue 2x magnets (10mm dia x 2mm thick) into the center bore at the bottom of the MAST Lower Shaft, and glue 1x magnet (5mm dia x 3mm thick) into the pocket at the top end of this part
STEP 5c: Glue 2x magnets (5mm dia x 3mm thick) into the pocket near the top of the MAST Upper Shaft. Please note that the outer magnet does protrude out slightly from the magnet hole (approx. 1.5mm). Then glue 1x magnet (5mm dia x 3mm thick) into the pocket at the bottom of this part.
STEP 5d: Glue 1x magnet (5mm dia x 3mm thick) into the pocket at the bottom of the MAST Head.

IMPORTANT: Push the magnet in as far as you can. It should sit approx. 1.5mm deep from the top of the hole.
STEP 5e: Glue the Service Loop _EL to the MAST Head
STEP 5f: Install the MAST Base_Front & Rear to the MAST Lower Shaft. These parts should be magnetically attach to each other
STEP 5g: Install the MAST Upper Shaft, and the MAST Head to the assembly above
STEP 5h: Glue the MAST Base_Mid to the Main Body from STEP 4
STEP 5i: Glue the MAST assembly to the Main Body

IMPORTANT: Only glue the bottom face of the MAST Base_Front & Rear to the Main Body. This would allow the MAST Assembly to rotate around this joint

STEP 6: Assemble the Robotic Arm

Parts required (refer to the photos below)

1x Main Body from STEP 5 (a)
1x Robot Arm Mount (b)
1x Robot Arm Joint 1 (c)
1x Robot Arm Joint 2 (d)
1x Robot Arm Shaft 1 (e)
1x Robot Arm Shaft 2 (f)
1x Robot Arm Joint 5 (g)
1x Coring Drill (h)
1x PIXL (i)
1x SHERLOC&WATSON (j)
1x Mars 2020 Plate (k)
1x Perseverance Plate (l)
1x Robot Arm Cable (m)
14x Magnet (10mm dia x 2mm thick) (highlighted in red)

Assembly process

STEP 6a: Glue 1x magnet (10mm dia x 2mm thick) into the pocket at the bottom of the Mount
STEP 6b: Glue 2x magnets (10mm dia x 2mm thick) into the pocket at the top of Joint 1. Please note that the outer magnet does protrude out slightly from the magnet hole (approx. 1mm)
STEP 6c: Glue 1x magnet (10mm dia x 2mm thick) into the pocket at the bottom of Joint 2
STEP 6d: Glue 2x magnets each (10mm dia x 2mm thick) into the pockets at each end of Shaft 1. Please note that the outer magnets does protrude out slightly from the magnet holes (approx. 1mm)
STEP 6e: Glue 1x magnet each (10mm dia x 2mm thick) into the pockets at each end of Shaft 2
STEP 6f: Glue 1x magnet (10mm dia x 2mm thick) into the pocket at the top of Joint 5, and glue 2x magnets (10mm dia x 2mm thick) into the pocket at the side. Please note that the outer magnet does protrude out slightly from the magnet hole (approx. 1mm)
STEP 6g: Glue 1x magnet (10mm dia x 2mm thick) into the pocket at the bottom of the Coring Drill. Then glue the PIXL, and SHERLOC&WATSON to the right, and left side of the Coring Drill respectively
STEP 6h: Glue the Mars 2020, and Perseverance plates to Shaft 1 & 2 respectively. Then assemble the Robotic Arm together. Please note that except Joint 1 & Joint 2 need to be glued together, all other parts should be held together only by magnets.

IMPORTANT: Magnets MUST be used as per instructions above to ensure all the joints move as design intent, so that the robotic arm is fully functional. Please DO NOT glue parts together where they are intended to magnetically attach to each other
STEP 6i: Glue the Mount to the Main Body from STEP 5
STEP 6j: Attach the Robotic Arm to the Mount
STEP 6k: Glue the Robot Arm Cable to the Main Body

Congratulations, you have fully built the Mars Rover PERSEVERANCE model at this point!