The objectives of this project were to 1) build a 3D model and print from scratch to accumulate hands-on CAD and prototyping experience for future modeling and printing projects, and 2) build a practical object—in this case, shelves resting on the windowsill in the Makerspace that can contain and display Benchys—3D boat models used for calibrating and benchmarking 3D-printing performance.

First, I measured the width of the windowsill (1.5”) and dimensions of a typical 3D Benchy (2.5” x 1.25” x 2.0”). Using those measurements, I used the outline and sketch features in the Fusion 360 software to create a shelf exactly 1.5” wide that would sit flush on our windowsill.

The dimensions of the compartment needed to be slightly larger than the dimensions of the Benchy to allow for movement. So, I sketched a rectangle surrounding the perimeters of the Benchy with an additional .25” of room for the width and height to allow for “tolerance” in the geometric dimensioning. I used the “mirror” action in Fusion360 to duplicate the compartments, totaling 4×4 or 16 shelves.

(I sketched a blue rectangle with the same length and height as the Benchy: 2.5” x 2.0”. This served as a helpful tolerancing reference.)

(I used the “extrude” feature in Fusion 360 to add a width of 1.5” to the original 2-dimensional sketch, thereby transforming it into a 3D model.)

Upon completing the 3D model and initializing the 3D printing process, I discovered that the model’s width and height exceeded the dimensions of the standard Prusa 1 MK3S bed. To solve this problem, I could have undergone another remodeling process to fit the dimensions or sliced the prototype and printed it in four iterations. Instead, I printed the original prototype on the larger Prusa XL. Looking forward to future projects, I’ll carefully consider the geometric dimensions of my 3D models relative to the volumetric constraints of the 3D printing devices to ensure successful prints.

Special thanks to Stepher Sabio (’28) and David Keiser-Clark, Makerspace Program Manager, for assisting in the 3D printing process!