Star Trek Com Badge with Magnetic Attachment

This model is just for fun.  I needed to print a bunch of Star Trek (TNG) communication badges for an activity, with only 1 day to complete them.  Most of the models available online were either too detailed (overkill for my needs), required a multi-material printer (I only have one, so that would have been a production bottleneck), required post-processing (painting), or were not suitable for FDM printers.

This model was developed quickly from pictures found online; it is not intended to be an exact replica, but is very close.  It is made from 3 pieces (oval base, insignia, and backplate for magnetic attachment).  This allowed it to be printed using 3 single-color printers in parallel.  This design is fast to print and inexpensive, making it almost expendable…perfect for crew members wearing red shirts (supply your own red shirt).

Design Features:

• No supports required
• Can be printed flat on the build plate
• Magnetic attachment to clothing
• Magnets on the backplate can be easily removed by using a 2.5mm hex wrench to push them out.

Parts Required:

• CA glue (thick or gel works best)
• 4 x 6x2mm Round Magnets.  I used these magnets from Amazon: 6x2mm Refrigerator Magnets

Printing Notes:

• PLA works fine for this model (unless you plan to visit the planet Vulcan, then use a higher temperature filament).
• Print the backplate using 0.2mm layer height, structural, 15% infill.
• Print the oval background and insignia using 0.15mm layer height (or smaller), structural, 15% infill.
• For the oval base and insignia, I used variable layer height for the upper layers to smooth out the gradual slopes and reduce layer line visibility (tapering down to 0.07mm layer height at the top layer).
• Supports are not required for any of the parts.
• Please DO NOT use the .bgcode files that have been provided (always slice your own files for your specific printer, filament, environment, etc.).  The files were only included to provide a reference for approximate print time.

Assembly Instructions (refer to photos):

Step 1:  Insert the magnets.  Press 2 magnets into the oval base piece and 2 magnets into the backplate.  Ensure that the magnets are flush with the surface, and are oriented such that the base and backplate will attract one another.  If you need to reverse the polarity, the magnets in the backplate can be pushed out from the opposite side using a 2.5mm hex wrench.  The easiest way to insert the magnets is to attach a magnet to a flat surface on the printer frame, line up the magnet hole on the printed piece, and press the piece against the printer frame until the magnet is flush; pliers can also be used.

Step 2:  Put 2 drops of thick CA glue on the oval base as shown, add the insignia, and hold the 2 pieces together for 30-60 seconds.

Step 3:  Enjoy!  Don’t forget your red shirt.

Miscellaneous Notes/Comments:

• The model in the photos was printed using Prusament Oh My Gold, and generic silver (don’t remember the brand).