Fusion 360 3D Printed Minifig Lego Head

I have created a regular sized minifigure lego head with Fusion 360. I picked the idea of a lego head to design because the idea of how legos fit together interested me and I love the way they look simple and miniature. I also wanted to see how close I would be able to recreate one with the basic cad skills I have learned at my Prairie Ridge, Illinois highschool IED class.

School: Prairie Ridge Highschool, Illinois

The only tools and materials used was Fusion 360 and a 3D printer from my school.

Start a new design for the lego head. Make sure in your document settings that you are using millimeters for Units. Start by drawing a circle on the x axis(face of plane facing up) with the sketch tool that has a diameter of 10.2. Then finish your sketch and extrude that circle up by 8.5. Next, fillet the edges of the top and bottom of that cylinder each for 2 mm. That is the basic portion of the head done.

Now it's time to make the stud at the top of the head and the hole at the bottom for its purpose of connecting to other lego pieces. First at the top center face of the cylinder sketch another circle and make it a diameter of 4.9. Then finish the sketch and extrude it up by 1.78. Add another sketch of a circle on the top face of the cylinder you just extruded with a diameter of 3.08. Then extrude it down by 1.78(cutting through the cylinder). Last for the stud on the top of the head fillet the edge of the top of the first cylinder extruded by 0.25. The next step will talk about the hole on the bottom of the head.

Now create a sketch at the bottom face of the head of a circle for the bottom hole that has a diameter of 6.2. Next extrude it down by 1.25. Then create another sketch on the bottom face of the extrusion with a diameter of 4.9. Exit the sketch and extrude the circle you just made, up into the cylinder by 5.793(make sure your cutting through the cylinder). Now you have made the bottom hole.

Lastly we can make the basic facial features such as the eyes and mouth of the lego head. Before we sketch the actual eyes and mouth, make sure you sketch a circular construction line at the top face of the hole(inside the head, 4.9 diameter) we made at the bottom of the head to mark where we want the center of the eye holes to vertically line up. Also make two construction lines going vertical and horizontal across the center of the head itself where the horizontal line is collinear with the construction line inside the head and the vertical line splitting the head straight down the middle. Now we can start making the eyes and mouth. First place a sketch of a circle anywhere on the horizontal line that is left of the vertical line(on the head) that has a diameter of 1(make sure the circle is NOT a construction line). Next set the distance between the center point of where the horizontal and vertical lines intersect AND the center of the circle(with sketch dimension) at 1.9. Then make another circle following the same steps as the last circle BUT instead place the circle anywhere to the right of the vertical line. Now use the symmetry constraint to give the eyes the same distance apart from eachother by clicking(with symmetry constraint selected) on the first circle with the distanced dimension(1.9), then the second circle and then the axis that you are going to reflect it across which in this case you would select the vertical construction line. The sketch of the eyes are now done.

Next is sketching the mouth. Still within the same sketch as the eyes, make a circle centered where the horizontal and vertical lines intersect and allow the circle to just touch the bottom line of the head before it starts the bottom fillet(about 5.086mm as the circle diameter). Next make another circle at the same center point as the first circle but the diameter is 4.5. Then make a line cutting horizontally only as long as the inside of the circle at 0.7 above the line just before the bottom fillet. Now remove all lines above the horizontal line that was just made from the two circles for the mouth using the trim tool. Also remove part of the horizontal line for the mouth that is within the inner diameter of the 4.5 diameter circle. The sketch of the mouth is now complete.

Now you can finish the sketch and start cutting the features into the head. Select the head by clicking on body 1 and move it back from the facial feature sketches by -6mm. Next select the extrude tool and select the eyes and mouth sketches and extrude it back by -2.5mm(make sure it's cutting into the head). Lastly you can move the head back by clicking on body 1 and moving it forward by 6mm. And that's it. You can look at the optional step below if you want to turn the head material yellow.

Select body 1 and right click it. Then select physical material. Scroll down in the pop up menu until you find plastics, then click on it and scroll down until you find Polymide(Kapton). Click and drag the material into the In This Design section just above the library of materials. From there the material should change to a yellow that would match the skin color of original lego figures heads.