3D Printed Sidewinder Missile Model

Sidewinder Missile Model:

This is a step by step tutorial on how i made a 1/2 scale model of the Sidewinder Missile (AIM-9). *Photos from Wikipedia.org and Weaponsystems.net

These are all the things needed to complete this project:

Tools:

1. Caliper
2. 3D printer
3. Two M4 4 cm screws
4. Screwdriver

Supplies:

1. PLA/PETG filament
2. Spray paints of your choice
3. Spray varnish and spray paint base
4. Glue
5. About 1 m of 60 mm PVC pipe (outer diameter)
6. Smoothing putty
7. Sanding paper

Designing process:

I started designing this model by creating a model of the PVC pipe I had. Its outer diameter is 60 mm, and the walls are 2 mm thick. For the whole process, I used the OnShape web-based CAD. The next steps involved designing the other parts of the missile around the model of the PVC pipe. The attached photos show the final outcome of my work.

3D Printing Instructions:

I recommend using PLA for all of the parts except the clamps, which can be printed in PETG for better flexibility. Print 4 of the lower flaps, 4 of the upper flaps, 2 clamps, and one of each remaining part. Use 10%–20% infill, and make sure to follow the instructions provided by your filament's manufacturer.

Drilling and Sanding:

While the parts are being printed, holes for the upper flaps can be drilled into the PVC pipe. The 4 holes should be placed along a line 92 mm from the end of the pipe, with equal distances between them. Next, sand the tips of the pipe smooth to ensure a good fit with the 3D printed parts.

Gluing and Sanding Instructions:

When all of the parts are printed, sand out any imperfections and glue them together. Use the slots in the lower body of the rocket to mount the lower ailerons, and the holes in the upper part for the upper ailerons. After gluing the whole model together, smoothing putty can be used to hide any imperfections and the seams between the glued parts. Make sure to align the lower flaps with the upper flaps before gluing the lower assembly to the PVC pipe.

Once everything is assembled, the sanding process can begin. Work your way up from 40 to 200 grit, and apply the smoothing putty as needed. Be sure to account for the curing time of the putty—sanding too early can cause it to fall off.

Painting Instructions:

When there are no imperfections, the spray base can be applied to the whole model. After it’s dry, apply your coloring of choice to the appropriate parts of the missile. For multicolor designs, use painting tape and paper sheets to mask off the areas that are not being painted a certain color.

Additionally, symbols and technical text can be added to enhance the realistic effect of the model. The file named USA_flag is a template that needs to be scaled to your own needs and 3D printed. It can then be used to spray-paint the flag symbol onto the rocket.

When everything is painted, varnish can be applied to the whole rocket. I recommend using both matte paint and matte varnish, as that is what most militaries use for missiles. The last photo shows all of the paints and varnish I used. The photos are arranged in the same order as the steps shown; you can use them for reference during your painting process.

Now you can enjoy your self made model of the Sidewinder missile!