This is a remix of https://www.thingiverse.com/thing:1658877 of which I really liked the pose. Once I started looking at the files it's clear why there are no reported prints. The model has lots of flaws including parts that don't or barely touch, parts from the right leg attached to the gun, incomplete right thumb, incomplete right leg, impossible to print legs on Ganymede (with a 0.4 mm nozzle at approx 250 mm model height), no wing thickness and bad wing orientation for Ganymede and others I've forgotten since I printed it last Christmas. I'm guessing its a basic game rip. Anyway I'm happy that it was posted because with some work in Zbrush I got it to print nicely.
Before posting this I checked other Bastion models and prints on Thingiverse and found that there is another version by intoxikated at http://www.semaker.com/productdetail/12052 Quite independently of me intoxikated has discovered a lot of the problems I did and put a lot of effort into fixing them too. So take a look at intoxikated's work as an alternative.
I wanted to print the model with as few pieces as possible because it was a rush job for Christmas presents for my kids. So this thing contains only five pieces (base/legs, torso/head, right arm, left arm, Ganymede). The original right leg was a mess so I mirrored the left leg and placed it in same pose as the source. I added keys and sockets to the parts to make placement and gluing easier (I'm a noob at this so they're barely useful). I thickened up Ganymede's scrawny legs so they would slice and print on my printer. Also thickened the wings and re-positioned them so they would print without much support. Bastion's left thumb was missing the final joint so I copied it from another Bastion thing somewhere (I think it's the source of the remix that I'm remixing) and attached it a'la Frankenstein's monster. Thickened up the shoulder pads which were hardly touching. Thickened up various "bones" so there were fewer gaps which would need support and fewer places to break. Thickened various gun plates so it would print and hold together better. Merged the legs into the stand. Did all this in Zbrush and decimated to give a reasonable quality water tight mesh.
Printed the torso in copper PLA. Printed the legs and arms in bronze PLA with yellow PLA for Ganymede. The metallic filaments change tone depending on lighting and viewing angle which was an unexpected bonus. I was just hoping for the look and feel of a metal statue. (Actually I wanted Bastion entirely in bronze but ran out of filament. However its was a fortunate problem because I'm happy with the mixture).
At 100% scale the base is 144 mm diameter with a total assembled height of about 250 mm.
Printer:
Anet A8
Rafts:
Yes
Supports:
Yes
Resolution:
0.2 mm
Infill:
20%
Notes:
I used Simplify 3D for slicing and printing with generous use of supports and rafts. They are generally easy to place manually after a first pass at automatic placement. But be warned. There are many nooks and crannies around the legs and torso, especially the head which has fine tubing, so patience and care is required to remove supports without damaging the print. Optimizing print orientation also helps minimize supports in troublesome areas. For example, torso layers lines show that it was not printed in a vertical orientation. This reduced the amount of support around the neck area in places where there is fine detail. Try loading each part in Autodesk MeshMixer and see what it suggests for print orientations. In the vertical orientation Ganymede takes a lot of support around his legs which requires careful removal, but his wings require none because the overhang angle is not too severe. With PLA I can generally print 60° +/- 5° without support. The odd shape of Bastion's arms means there are no flat spots to form the base of a print. So I used lots of support built on top of a raft to ensure the supports where held firmly in place.
I don't recall specific print details but at 0.2 mm layer height and default print speed of 60 mm/s (average is more like 30 according to G-Code Analyser http://www.gcodeanalyser.com/ which I use all the time for accurate time estimates) I got print times of (hh:mm) 8:49, 7:20, 5:49, 2:22, for legs, torso, arm_R, arm_L respectively. Ganymede took 1:36 at set speed of 30 mm/s.
