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Bringing the enchantment of Disney parks into your home is now achievable with innovative technology. Inspired by magical memories at Disneyland and the captivating castle fireworks, one enthusiast utilized the Elegoo OrangeStorm Giga 3D printer to create a unique home display. While this expansive 3D printer may exceed the needs of typical hobbyists, its large-scale capabilities are ideally suited for ambitious projects like crafting an impressive, projectable Disney castle replica. This article explores the journey of creating a personalized Disney fireworks experience at home using 3D printing and projection.
Embarking on the Project: The Inspiration
3D printing presents vast possibilities, ranging from practical repairs to elaborate artistic creations. For those who routinely evaluate top 3D printers, access to diverse machinery allows for comprehensive testing. While standard evaluations involve intricate test models to assess printer performance, sometimes personal projects take precedence, driven by passion and nostalgia.
The Genesis of an Idea
The concept originated from a TikTok video by Alex Carrao, showcasing a 3D-printed Disney castle enhanced with a projected fireworks display. The goal was to emulate the nightly spectacle at Disney parks, a seemingly straightforward endeavor. Carrao’s original Disney World castle was designed for standard-sized 3D printers (approximately 250x250x250mm). However, with access to a larger format printer, the ambition grew to create a more substantial Disneyland castle.
Choosing the Castle and Model Adjustments
The decision was made to replicate Disneyland’s Sleeping Beauty castle, a personal favorite, rather than Disney World’s Cinderella castle. Fortuitously, Alex Carrao offered 3D models for both. After acquiring the Disneyland castle model, modifications began to align it with the project’s purpose. Since the projection would focus on the central castle area, the model’s extended barrier walls were deemed unnecessary. These superfluous elements were efficiently removed using Microsoft’s 3D Builder software. With the model refined, it was ready for the printing stage.
The sheer size of the OrangeStorm Giga 3D printer is remarkable.
Unleashing the OrangeStorm Giga
The capabilities of the OrangeStorm Giga 3D printer are immense. Boasting an expansive 800x800x1,000mm build volume utilizing four 400x400mm build plates, this printer sparked considerable excitement upon its initial announcement. While engaging and enjoyable to experiment with, its complexity, demanding setup, and substantial size may deter casual users lacking a dedicated workshop. Nevertheless, for those with ample space, patience, and resources, the $2,500 investment unlocks the potential for truly extraordinary creations.
Scaling and Printing the Castle
After meticulous calibration, the printer was deemed ready to undertake the castle project. The model was enlarged to achieve a 700mm width upon completion. STL files, the standard for 3D printing, accommodate scaling effectively, though excessive enlargement can compromise fine details. In this instance, the castle’s relatively simple design, intended as a projection surface, mitigated this risk.
A sizable spool of Overture filament was essential for this substantial print.
Print Duration and Material Consumption
The entire printing process spanned slightly over 85 hours. For a 3D model of this scale and material volume, this duration is considered rapid. As a point of comparison, printing a full-sized Mandalorian helmet five years prior required 125 hours and consumed only a fraction of the material used for the castle.
Material usage was substantial, requiring nearly an entire 3-kilogram spool of Overture PLA filament, even with an 8% gyroid infill density. The resulting print is robust and weighty, ensuring wall-mounted stability.
Enhancing Aesthetics: Primer and Paint Application
Achieving the desired smoothness required two full cans of primer filler.
Surface Preparation and Finishing Touches
Preparation for projection involved refining the 3D-printed surface. Automotive primer filler was applied to minimize layer lines, using two cans to achieve a smooth texture without obscuring the brickwork detail. Subsequently, two cans of stone effect spray paint provided an appealing finish. The color choice was deliberate; avoiding dark or vibrant hues ensured the castle remained a neutral projection backdrop while maintaining aesthetic appeal as a standalone wall decoration. The stone color harmonizes with the wall, concealing its 3D-printed origins.
Exploring Projection Paint Alternatives
Projector paint was considered to potentially enhance the projected fireworks’ visual quality. However, its high cost—over $100 per can, exceeding the combined material expenses—rendered it impractical. The standard painted surface would have to suffice, relying on projector capabilities for optimal display.
Projection Setup and Refinement
Projector Selection and Video Criteria
Achieving perfect projection remains a challenge, limited by available technology. An Xgimi Elfin projector, while older, offered YouTube and Android TV access and, crucially, portability for angle adjustments. Key video selection criteria included:
- Tripod-stabilized filming
- Minimum 1080p resolution
- Absence of foreground obstructions
- Focus solely on the castle, excluding surrounding areas
A suitable video was found after extensive searching: the DizFeed Disneyland Forever video. This selection held personal significance, depicting the fireworks show from a cherished honeymoon memory. Beyond technical suitability, the video evoked nostalgic sentiments, enhancing the project’s emotional value.
The Elfin projector’s keystone correction was utilized, despite limitations.
Image Adjustment and Focus
Projector image scaling was achieved using keystone correction. This feature, common in leading projectors, compensates for projector placement, correcting trapezoidal distortion. For this project, keystone correction resized the video to precisely fit the 3D-printed castle. Shadowing and potential focus issues arose due to the model’s protrusion from the wall. Focus optimization prioritized the central window area, the primary action zone. While not flawless, the result proved satisfactory, short of employing multiple projectors for comprehensive coverage.
Future Enhancements and Project Reflections
Artificial clouds are being considered to elevate the visual appeal.
Potential Upgrades
Further refinement would entail additional investment. A more advanced projector with enhanced keystone correction capabilities would improve image fidelity. Alternatively, a laptop could manage video output adjustments, though concealing it behind the projector presents logistical challenges. A Raspberry Pi offers a more compact solution, potentially integrated into a 3D-printed Main Street-themed shelf for discreet placement.
Adding Atmospheric Elements
Incorporating artificial clouds below the castle is being considered to enhance visual appeal and create a floating illusion. This addition could also soften the video cutoff point, promoting a more seamless and natural aesthetic.
Project Summary
This project proved to be a rewarding and enjoyable endeavor, reaffirming the motivations for entering the realm of 3D printing: creative expression and personal enjoyment. The Disney castle with its nightly fireworks display fulfills both objectives, providing daily nostalgic joy and a reminder of cherished memories.
Recreate the Magic: Disney Fireworks at Home
For those inspired to create their own Disney fireworks display, potentially on a smaller scale, the following list outlines essential components, including major purchases like 3D printers and projectors.