Life Sized 3D Printed BD-1

Jedi: Fallen Order / Survivor

The game series following Cal Kestis and his droid companion has to be one of my all time favorite games (The following images are from that game, I do not own these)

Playing this game inspired me want to make multiple things from the game, the two first ones being my custom lightsaber that I made in the game, and Cal Kestis's droid companion BD-1

The Build

Unfortunately I did not model BD-1 and found a very good file off of Thingiverse by Fine_Engineer

But I knew that just by having the files only got me half of the way there, I still had to do all the post processing necessary to get a good result

So approximately 174 hours of printing on PETG filament later... and with the gray pieces with post processing already...

This doesn't show all of the parts, some are already glued together and look like 1 piece. The idea behind the pieces is so that the dark gray pieces looks like worn metal, with all the scratches and imperfections

Basic Process for Each Piece

White pieces shown were painted white first and dark gray pieces had to be painted black and faint gray. Then I would move onto the red parts, using masking tape to only get the parts that I wanted to paint. The metallic look was achieved using a product called "Rub'n Buff", and I used a silver Rub'n Buff to get the metallic wear look. I then went over the paint job with either Rub'n Buff or a gray paint to get more of the wear look around the whole figure. To then top it off, I sprayed a layer of clear acrylic over the top to seal it all off

Final Steps

The final step was to add electronics so that the eyes light up, and using a battery and 2 blue LED's it was a very quick add

For the paint job I was really inspired by the show Star Wars: The Clone Wars, and really wanted to simulate the layering and brush stroke art style that this show uses. There is a lot of weathering, but every square inch of this build was intentional, down to the smallest scratch and smear