# How To Print Over Sized Objects

**URL:** <https://forum.lulzbot.com/t/how-to-print-over-sized-objects/2444>\
**Category:** Software\
**Created:** [November 9, 2015, 6:59pm UTC](https://forum.lulzbot.com/t/how-to-print-over-sized-objects/2444 "2015-11-09T18:59:52Z")\
**Posts on this page:** 4\
**Page:** 1

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**Author:** ![SudoICE](https://avatars.discourse-cdn.com/v4/letter/s/34f0e0/32.png) [@SudoICE](https://forum.lulzbot.com/u/SudoICE)\
**Post date:** [November 9, 2015, 6:59pm UTC](https://forum.lulzbot.com/t/how-to-print-over-sized-objects/2444/1 "2015-11-09T18:59:52Z")

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Here is a how-to method that I use to print over sized objects. I use ABS for functional parts and Acetone to weld the parts together. However, I like using dovetail type joints along with the acetone. The software I use to create a kerf with the dovetail shape is Autodesk’s Fusion 360 [http://www.autodesk.com/products/fusion-360/try-buy](http://www.autodesk.com/products/fusion-360/try-buy) which is “Free for students, enthusiasts, hobbyists, and startups.” This weekend I needed to print an upper\_z plate for my TAZ 6 project I am starting and the Mini I have will not print that large.

Summary:  
Step 1. Download Fusion 360 and then upload your part.  
Step 2. Convert the shapefile to a solid.  
Step 3. Draw a dovetail where you want to split the parts.  
Step 4. Extrude a 0.3 mm gap through the parts.  
Step 5. Export the two parts for printing and assembly.  
Step 6. Assemble

Download an STL of the file you wish to cut. The file I used for this tutorial is upper\_z\_v1.0.stl.

![](http://i.imgur.com/SGU6TkW.png)

Open Fusion 360 and upload the file.

![](http://i.imgur.com/CQ1n3Nz.png)

![](http://i.imgur.com/atMJXU4.png)

After the upload is complete, open the part.

![](http://i.imgur.com/UhPmqiH.png)

Change the workspace to Model, and click Modify -\> Mesh -\> Mesh to BRep

![](http://i.imgur.com/JcDN4f5.png)

Select the object and click OK to create a New Body. This may take a few seconds.

![](http://i.imgur.com/zAHZ55q.png)

At this point your object is now a solid.

![](http://i.imgur.com/sv4KPyR.png)

Now create a sketch on the surface. Click Sketch -\> Create Sketch.

![](http://i.imgur.com/M1s9Gpv.png)

Select the surface/plane where you will draw.

![](http://i.imgur.com/E2jBlbB.png)

![](http://i.imgur.com/24sWW2K.png)

Draw some lines by selecting Sketch -\> Line. The dimensions I use are 20mm out, 10mm back @ a 125degree angle.

![](http://i.imgur.com/5Kixr5U.png)

Draw the same pattern on the other side and then connect the two segments.

![](http://i.imgur.com/bnWB3WL.png)

At this point we have the shape of our dovetail and want to offset that shape by 0.3 mm.  
Select Sketch -\> Offset.

![](http://i.imgur.com/zKNnwBF.png)

Select the middle section, drag to the left, and type in .3, press enter. Also repeat for the other two lines.

![](http://i.imgur.com/CZaDHuR.png)

Zoom in on your corners and trim up the extra segments. Click Sketch -\> Trim.

![](http://i.imgur.com/LNQWxPB.png)

Highlight and left-click the segments you want to remove.

![](http://i.imgur.com/nlW1H1f.png)

The end result should be a clear channel for the kerf.

![](http://i.imgur.com/d3vJO0D.png)

Draw a line between the original and offset lines to create a closed area to extrude, top and bottom.

![](http://i.imgur.com/NVbQcAZ.png)

Click Create -\> Extrude.

![](http://i.imgur.com/aRiMaaK.png)

Highlight your kerf, hold down Ctrl for multiple selections. Type in an extrude distance = or \> the depth of cut and click ok.

![](http://i.imgur.com/Q0zZmMk.png)

Here is an angled perspective of the cut.

![](http://i.imgur.com/sBpcT44.png)

You should see a gap between what is now two parts.

![](http://i.imgur.com/2CG141y.png)

To export the parts, click on Make and select one part. Repeat to export the second part.

![](http://i.imgur.com/Meiuhw5.png)

Open in Cura or your slicer of choice and print.

![](http://i.imgur.com/cpIOCja.png)

Printed part:

![](http://i.imgur.com/iYagFpB.jpg)

For assembly, trim the parts if necessary and snap together.

![](http://i.imgur.com/mfSScjb.jpg)

![](http://i.imgur.com/tNHC2bj.jpg)

Finally, I use a knife blade and dip it into acetone, then hold it over the seam I want to weld. A drop at the time.

![](http://i.imgur.com/jBlGx6w.jpg)

![](http://i.imgur.com/b5iVkXB.jpg)

I was amazed at how strong of a bond this makes. In other examples I tried to break the part and succeeded but somewhere other than the welded seam. Make sure to let the acetone fully dry. 20-30 min? Try it!

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<div class="post-metadata">

**Author:** ![nickthetait](https://avatars.discourse-cdn.com/v4/letter/n/ac8455/32.png) [@nickthetait](https://forum.lulzbot.com/u/nickthetait)\
**Post date:** [November 9, 2015, 8:21pm UTC](https://forum.lulzbot.com/t/how-to-print-over-sized-objects/2444/2 "2015-11-09T20:21:43Z")

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Quite the detailed tutorial. I like it!

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**Author:** ![i-t-w.com](https://sea2.discourse-cdn.com/flex020/user_avatar/forum.lulzbot.com/i-t-w.com/32/65_2.png) [@i-t-w.com](https://forum.lulzbot.com/u/i-t-w.com)\
**Post date:** [November 12, 2015, 1:21am UTC](https://forum.lulzbot.com/t/how-to-print-over-sized-objects/2444/3 "2015-11-12T01:21:26Z")

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Great writeup, thanks!

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<div class="post-metadata">

**Author:** ![markevans36301](https://avatars.discourse-cdn.com/v4/letter/m/b5e925/32.png) [@markevans36301](https://forum.lulzbot.com/u/markevans36301)\
**Post date:** [November 12, 2015, 9:34am UTC](https://forum.lulzbot.com/t/how-to-print-over-sized-objects/2444/4 "2015-11-12T09:34:27Z")

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Very nicely done. You should expand it on out into an instructable.