Whirligig, Butterfly.

After completing "Whirligig, Pterodactyl", a Youtube follower suggested that I use the butterfly from a previous project of mine and create a butterfly whirligig. Little did he know that I had just completed adapting the butterfly to a whirligig mechanism, and this model, "Whirligig, Butterfly" is the result!

I 3D printed my butterfly whirligigs in Tough PLA to assist in withstanding the weather. This whirligig has experienced wind speeds of over 20mph with gusts into the 30s. However, at the end of the day I slide the butterfly off of its mount and take it inside in order to hopefully prolong its life!

As usual, I probably forgot a file or two or who knows what else, so if you have any questions, please do not hesitate to ask as I do make plenty of mistakes.

Designed using Autodesk Fusion 360, sliced using Ultimaker Cura 4.12.1, and 3D printed in Tough PLA on Ultimaker S5s and an Ultimaker 3e.

Thick cyanoacrylate glue.

Double sided tape.

I acquired the following parts:

• One 16mm diameter ball bearing.
• One M8 by 1.25 threaded rod.
• One M8 by 1.25 nut.
• Two F688ZZ flanged bearings (5mm thick, 16mm outside diameter, 8mm inside diameter).

I 3D printed the following parts at .15mm layer height, 20% infill in Tough PLA unless noted otherwise:

• Two "Arm Wing.stl".
• One "Axle Wings.stl".
• One "Base.stl" (supports optional).
• One "Bearing Mount.stl".
• One "Cam.stl".
• One "Drill Guide.stl", 100% infill, PLA.
• One "Flower.stl".
• One "Head.stl".
• One "Mount Cap.stl".
• One "Mount.stl".
• Two "Pin Wing.stl".
• One "Pin Yoke.stl".
• One "Propeller.stl".
• One "Retainer.stl".
• One "Tail.stl".
• One "Wings.3mf".
• One "Yoke.stl".

This is a high precision 3D print and assembly model using at times very small precision parts in very tight spaces. Prior to assembly, test fit and trim, file, sand, polish, etc. all parts as necessary for smooth movement of moving surfaces, and tight fit for non moving surfaces. Depending on you printer, your printer settings and the colors you chose, more or less trimming, filing, sanding and/or polishing may be required. Carefully file all edges that contacted the build plate to make absolutely certain that all build plate "ooze" is removed and that all edges are smooth. I used small jewelers files and plenty of patience to perform this step.

The model also uses threaded assembly thus an M8 by 1.25 tap and die will assist with thread cleaning if necessary.

To assemble the butterfly, I performed the following steps:

• Attached one "Arm Wing.stl" to left wing arm mount using one "Pin Wing.stl" making certain the arm pivoted with ease (a small dot of glue where the pin tip protrudes through the wing may be needed to secure the pin in place).
• Repeated the previous step for the right wing.
• Pressed "Axle Wings.stl" into "Head.stl" (note the flat side of the axle faces downward).
• Positioned the wings together, then slid the axle through the wing pivots.
• Pressed "Tail.stl" onto the free end of the axle.

To assemble the base, I performed the following steps:

• Pressed one ball bearing into the inside bearing pocket in "Base.stl".
• Pressed the remaining ball bearing into the outside bearing pocket in the base assembly (small dots of glue in the bearing pocket flanges may be needed to secure the bearings in place).
• Positioned "Yoke.stl" over the pin in "Cam.stl" then secured it in place with "Retainer.stl".
• Slid the yoke assembly up through the base and out through the stem.
• Threaded "Flower.stl" onto the base assembly making certain the butterfly mount pocket faced rearward.
• Pressed the butterfly assembly mount into the butterfly mount pocket on the flower, then attached the two wing arms to the yoke using one "Pin Yoke.stl" (a small dot of glue where the pin tip protrudes through the yoke may be needed to secure the pin in place).
• Slid "Propeller.stl" axle through the base assembly ball bearings, into the cam compartment, then threaded it into the cam.

For final assembly, I performed the following steps:

• Glued "Mount Cap.stl" into "Mount.stl" such that the cap was flush with the top of the mount.
• Applied four pieces of double sided tape to the top of the mount assembly then over the edge to the top of the mount flange.
• Pressed the mount assembly into the base assembly.
• Threaded 80mm length of thread rod into "Bearing Mount.stl"
• Threaded the nut onto the threaded rod tightly against the bearing mount to secure the threaded rod into position.
• Placed the ball bearing into the bearing mount cup.
• Slid the bearing mount assembly into the mount.

And that is how I 3D printed and assembled "Whirligig, Butterfly".

I hope you enjoyed it!

The part "Drill Guide.stl" is what I used to drill a centered hole in the mounting poles for my whirligigs. I've attached a video of how I designed and used the drill guide to create the centered holes.

I used a 6 foot section of 1 5/16" diameter poplar pole. I recommend painting the pole to preserve it in bad weather.