Layer By Layer

Layer 06 — Life-Size Han Solo in Carbonite (Body Panel)

Large-scale multi-part display print documented for Layer by Layer.

This project is a life-size Han Solo in Carbonite body panel, printed in multiple sections and assembled into a full-scale piece. The carbonite surround and frame still have to be built, but the centerpiece of the project is officially printed.

Material & settings:
• Printer: Bambu Lab P1S
• Filament: PLA
• Nozzle: 0.4 mm
• Layer height: 0.16 mm
• Walls: 3
• Infill: 10% Gyroid
• Outer wall speed: 60 mm/s
• Adaptive/variable layer height: Used where additional detail mattered, especially the face and upper body

The goal with this print was pretty straightforward — print Han Solo in Carbonite at life size without spending a small fortune doing it.

Because the body had to be divided into multiple sections, maintaining consistent quality across every piece was important. I used a 0.16 mm layer height throughout, with adaptive layer heights in areas where the extra detail would actually make a difference, particularly around Han's face and upper body.

Once all of the sections were finally printed and assembled, the numbers were a little ridiculous.

214.1 print hours — 8 days, 22 hours, 6 minutes of nonstop printing.

3,530g of filament — 3.53 rolls.

Approximately $34.93 in filament used.

For something this large, the actual material cost is probably one of my favorite parts of the build. Three and a half rolls of PLA and less than $35 in filament turned into a life-size Han Solo in Carbonite body panel.

Of course, printed doesn't mean finished.

Next comes probably the least glamorous part of the entire project: filling seams, sanding, and trying to make all of those individual printed sections disappear before moving on to paint.

And after that, I still have to build the entire carbonite surround and frame.

There’s still a long way to go, but after more than 214 hours of printing, Han is finally in one piece.

On to the next layer.

Layer 05 — Life-Size FIFA World Cup Trophy (Large Scale Display Print)

Large-scale display print documented for Layer by Layer.
This print uses a life-size FIFA World Cup trophy model designed as a seamless display piece with AMS accents on the base.

Material & settings:
• Printer: Bambu Lab P1S
• Filament: PLA Silk Gold & PLA Silk Green
• Layer height: 0.16 mm
• Colors: 2 (AMS used for base accents)
• Orientation: Upright vertical print
• Plate: Textured PEI
• Supports: Minimal supports required

The goal of this print was simple — make a piece of plastic look like something that belongs in a trophy case.

The main body of the trophy was printed in PLA Silk Gold to give it that reflective metallic look, while PLA Silk Green was used on the base through the AMS system to help break up the colors and give the display a more finished appearance.

Large silk prints can be unforgiving since the shiny finish highlights every little inconsistency, so keeping the layers clean and stable throughout the print was important. Since this was printed upright at full scale, consistency became a bigger factor than speed.

One of the best parts of this model is that it was designed to minimize visible seams and avoid excessive assembly, which helps the finished print look much cleaner once completed.

And honestly… there’s something funny about 3D printing in 24 hours what Lionel Messi spent 20 years chasing.

Overall, the print completed successfully and ended up being one of those projects that instantly grabs attention from across the room.

On to the next layer.

Layer 04 — Greetings, Programs.

This one’s a stylized Recognizer from TRON. No big design experiment here — I just wanted something fun for the office wall, and I’ve always loved TRON.

Kept it simple on purpose. No lighting, no extras… just a clean silhouette and strong contrast that makes it instantly recognizable if you know it.

Material & settings:
• Printer: Bambu Labs P1S
• Filament: Sunlu Matte PLA (Black, Red)
• Layer height: 0.20 mm
• Nozzle: 0.4 mm
• Walls: 2
• Infill: 15%
• Colors: 2 (printed using AMS)
• Orientation: Graphic facing up
• Plate: Textured PEI
• Supports: None required

The matte finish worked really well here. The black keeps it clean and the red edge lines give it that TRON feel without needing anything extra.

With a design this simple, it really comes down to clean edges and keeping everything consistent.

If you recognize it, you recognize it.

Greetings, Programs.

On to the next layer.

Layer 03 — Iron Maiden “Trooper” Coasters (AMS Multi-Color Test)

First multi-color print documented for Layer by Layer.

This print uses an Iron Maiden “Trooper” coaster design, inspired by the artwork associated with the Trooper beer branding and Eddie character.

Material & settings:
• Printer: Bambu Labs P1S
• Filament: PLA (Black, White, Red, Blue)
• Layer height: 0.12 mm
• Colors: 4 (printed using AMS)
• Orientation: Graphic facing up
• Plate: Textured PEI
• Supports: None required

The purpose of this print was to test my first four-color print using the AMS system. Multi-color prints can look intimidating at first due to filament changes and purge towers, but the AMS handled the color swaps smoothly throughout the print.

Color registration came out clean and the bold graphic worked well for a multi-color test. Printing the design facing up leaves the natural texture of the layer lines visible in the colored areas, but the overall contrast and detail still came through clearly.

Overall, the print completed successfully and served as a solid first step into AMS multi-color printing.

On to the next layer.

Layer 02 — John Hammond’s Cane

Starting a new Layer.

This project is a recreation of John Hammond’s cane from Jurassic Park, documented from the first print through final finishing and assembly. Instead of buying a high-end replica, the goal is to build it properly, understand the construction, and finish it intentionally.

In the film they say “we spared no expense.”
For this build, we’re doing things a little differently.

We spared some expense.

First updates will follow as the core segments come off the printer.

Layer 02 is printing.

New approach, new variables.
Full notes once it’s done.

Layer 01 — Heavy Icons Stormtrooper

First print documented for Layer by Layer.

This is the Heavy Icons “Inspired by Stormtrooper” model from MakerWorld:
🔗 https://makerworld.com/en/models/1755674-heavy-icons-inspired-by-stromtrooper?from=search -1867009

Material & settings:
• Filament: 3DHojor Light Khaki Matte PLA
• Layer height: 0.12 mm
• Variable layers: 0.08 mm from the shoulders upward (already set in the 3MF file)
• Supports: Auto supports enabled

The print finished successfully, but not perfectly. Supports failed under the left arm of the couch and later under the blaster and hand, which caused visible scarring where those areas printed without proper backing.

I’m keeping it as-is and documenting the lesson instead of reprinting. Auto supports handled most of the model well, but thin, forward-extending geometry clearly needs manual support attention next time.

On to the next layer.

Welcome to Layer by Layer!

Layer by Layer is a 3D printing log.

This page documents prints as they actually happen — successes, failures, reprints, fixes, and finishes. Some projects are complete display pieces, others are test fits or experiments. Not everything goes perfectly, and that’s intentional.

A quick note up front: I am not an expert.
This is only the third 3D printer I’ve ever owned, and I’m currently printing on a Bambu P1S. I’m still learning, still experimenting, and still figuring things out as I go.

The goal of this page isn’t to teach from a pedestal — it’s to document the journey. Different filaments, different techniques, different problems, and real-world results. What worked, what didn’t, and what I’ll change next time.

There’s no posting schedule here. New entries go up when there’s something worth sharing.

The first entry is live now: a Stormtrooper print that finished despite partial support failure, with notes on what worked and what I’ll change next time.

Thanks for following along — more layers to come.