Fun N' Learn "ALPHABET PYRAMID"

My son has lately started talking and also developed some interest in toys like LEGO bricks and jigsaw puzzles. Secondly I too began learning 3d designing and 3d printing for quite some time now.

Hence I thought of giving a little boost to our enthusiasm by making this project (ALPHABET PYRAMID).

It has four layers, wherein first three layers have support pillars so that subsequent layers can rest upon them.

Each layer holds specific alphabets, and the layers may be assembled (or solved) separately and then stacked one above the other.

It is easy to detach and stack the layers, as they are joined using magnets (Depicted in later steps)

I used "Sketchup" for 3d designing and "Creality ender 3" for 3d printing. Some magnets to attach layers together and glue to stick the magnets. Sandpaper and knife to clean the printed parts.

3D designing was carried out in "Sketchup". So you will need to download extension to export STL files for Sketchup if you wish to use Skecthup for 3d printing a designed part.

However, I have uploaded the STL files if you wish to directly print without going for designing.

The bed size of Ender 3 is 220 x 220mm, hence I printed the alphabets in two sets. Separate files for each layer as well. Slicing of STL files was done using "Ultimaker Cura".

Cura settings are as follows:

PLA material

Printing temp. - 200 degrees

Bed temp. - 55 degrees

Layer thickness - 0.4mm (for layers) 0.2mm (for alphabets)

Wall line count - 3

Top and bottom layers - 3

Infill - 10% (for alphabets) and 20% (for layers)

Supports ON (to print supports for pockets made for inserting magnets)

These are few settings which I thought of mentioning, if you want any other setting details, then please comment.

The printing time taken was approximately 10 hours. You may decrease the printing time by changing the printing speeds in Cura or on the printer itself.

Once the printing is complete, you may have to clean some of the alphabets and alphabet sockets on the layers (for irregularities and burs) using sandpaper and sharp knife to allow proper fitment of alphabets.

Check for each alphabets fitment in their respective sockets. (Most of the alphabets fitted perfectly in my case, while some needed a bit of rework)

Since I used magnets for layer attachment, I had to widen the holes for inserting the magnets. I used glue to sitck the magnets inside the holes in order to avoid the magnets from popping out of the holes.

Once the post printing activity is complete, you may start enjoying it with your kids.....

The Alphabets and layers can attached and detached multiple times allowing the activity to be played multiple times.

I thought this project would be done very easily, but it took me a lot of time for re-designing as there were a few failures early on. Also the post printing activity troubled me, but fortunately there was very little stringing caused and the prints came out clean.

It seems an easy activity for adults, but kids do enjoy the activity of assembling the pyramid.

THANKS FOR READING THROUGH.......