Bring Your Action Figures to Life with 3D Printing

Action figures have been a popular toy for kids and collectors for decades. Brands like G.I. Joe, Transformers, and Star Wars have produced countless versions of poseable plastic figurines ready for adventure. But what if you want an action figure that’s truly one-of-a-kind? That’s where 3D printing comes in.

With 3D printing technology, you can design and print completely custom action figures at home. Whether you want to create a miniature version of yourself, reproduce a rare collectible, or just bring your imagination to life, 3D printed action figures make it possible.

In this complete guide, we’ll cover everything you need to know about making 3D printed action figures, from design and modeling to finishing and painting. Let’s get started!

Designing Your Custom Action Figure

The first step is designing your 3D model. You have a few options here:

1. Design from Scratch

For full creative freedom, you can design your action figure from scratch using 3D modeling software like Blender or Sculptris. This takes some 3D modeling experience, but allows you to create a unique character. Focus on shapes, proportions, and articulation points.

2. Scan Yourself

If you want a mini “you,” there are apps that let you scan yourself using just your smartphone camera. It will map a 3D model of your body that you can size down and refine. Popular scanning apps include Scandy, ShapeScale, and Canvas.

3. Modify Existing Models

You may be able to find a premade 3D model online that you can tweak to your liking. Sites like TurboSquid and Sketchfab offer 3D models, sometimes for free. Look for ones with humanoid shapes and clean topology.

Articulation and Posing

Part of the fun of action figures is being able to pose them acting out scenes. When modeling your 3D design, plan out areas for articulation—joints or swivel points that allow repositioning of limbs.

Common articulation points include:

• Neck
• Shoulders
• Elbows
• Wrists
• Waist
• Hips
• Knees
• Ankles

Ball joint and hinge connectors work best. Test your model’s poseability before printing.

Choose Your Printing Material

FDM 3D printers work well for printing action figures using plastic filament. Good materials include:

• PLA – Smooth finish, easy to work with, not super durable
• ABS – Tougher than PLA, more prone to warping
• PETG – Stronger than PLA, easier to print than ABS
• Flexible filament – For joint areas to allow positioning

Resin 3D printers, using photocurable resin, achieve greater detail and smoothness. Resin is harder to work with and requires more cleanup than filament.

For tiny details like faces, SLA printers or DLP printers are recommended. But FDM can still achieve good results with a smaller nozzle size like 0.2mm.

Print Your Action Figure

When slicing your model for printing, orient it thoughtfully to minimize support material. Arms and legs should stick out to avoid too many overhangs.

Slow down the print speed for better precision on small features. A layer height of 0.1mm or 0.2mm will give good detail. Dial in your retraction, temperature, and extrusion multiplier settings for clean, strong prints.

For stability when posing, add a base to connect feet to. Use rafts or brims when printing to avoid warping. Sand and fill any layer lines for a smooth surface.

Assembling Multi-Part Prints

Larger figures may need to be printed in sections and assembled. Design with connectors in mind. Sockets, cross pins, adhesive, and even string can join parts.

Minimize seams by planning out best print orientation per section. Use acetone vapor baths to weld ABS pieces together.

Painting and Finishing

A great paint job can really bring your custom action figure to life. Give it a signature look with quality paints.

Sanding lightly will prep the surface for painting. A filler putty helps smooth imperfections and filling layer gaps. Then a primer coat provides a uniform foundation.

Acrylic craft paints work well for hand painting. Opt for modeling paints like Citadel or Vallejo for durability and vibrancy. Use thin layers of paint, allowing drying time between coats.

Consider washes to enhance contours and details. Accent painted areas with colored pencils or markers for an extra pop. Apply a matte varnish to protect the painted surface.

Advanced Options

Beyond basic action figures, 3D printing opens up opportunities for more advanced models:

• Posable endoskeleton – Design an internal skeleton for enhanced articulation. Print in sturdy material like carbon fiber PLA.
• Kitbashing – Mix and match parts from various sources to create your own mashup character.
• Dioramas – Print miniature 3D environments and props to display your figure in action.
• Texture Mapping – Add finer surface details like skin pores and wrinkles using programs like ZBrush.

Best Practices for 3D Printed Action Figures

Follow these tips for successful prints:

• Minimize overhangs that require supports
• Use a small layer height, around 0.1 – 0.2mm
• Choose flexible filament for movable joints
• Print upright with feet attached to the build plate
• Allow proper drying time for resin before handling
• Sand and finish for smooth surfaces and paint adhesion
• Insert pins into joints to reinforce connections

Action Figure File Formats

Common file formats for 3D printing action figures include:

• STL – Standard mesh format, compatible with most software and printers
• OBJ – Popular 3D model format retaining texture and color info
• 3MF – Improves on STL with more compact code and color support
• GCODE – Machine code instructions for the 3D printer

Scale Your Action Figure Correctly

Consider the intended size of your action figure early on. Smaller scales allow more detail but are trickier to print.

Typical scales include:

• 1:6 scale – 12 inches tall, popular size for many collectibles
• 1:12 scale – 6 inches tall, common for crowdfunded figures
• 1:18 scale – 4 inches tall, good desktoy size

Check printer limitations and adjust model dimensions as needed. The larger your print, the more likely you may need to split it into parts.

Best 3D Printers for Action Figures

You don’t need an industrial grade machine to print great action figures at home. We recommend these accessible consumer 3D printers:

• Original Prusa i3 MK3S – Workhorse FDM printer with excellent print quality
• Creality Ender 3 series – Budget printers with strong community support
• Anycubic Photon – Affordable resin printer for miniatures with fine details
• Formlabs Form 3 – High resolution SLA for prosumer use

Look for at least 0.1mm nozzle capability, a heated bed, and 7.5” x 7.5” x 7.5” build volume to accommodate larger figures. Enclosed chambers help control temperatures for better printing with materials like ABS.

Top 3D Modeling Programs

To design your own action figure from scratch, use 3D modeling software. Top options include:

• Blender – Free and open source 3D creation suite for the full modeling workflow
• ZBrush – Specialized digital sculpting app great for organic models
• Fusion 360 – CAD software with mesh sculpting tools and customizable joints
• Sculptris – Beginner friendly digital clay sculpting with dynamic tessellation

Look for features like subdividing polygons, dynamic topology, posed armatures, and repeatable patterns to speed up creation of models. Assembling premade parts is also a quick option.

Where to Find 3D Models for Action Figures

If you don’t want to model a figure from scratch, you can source 3D models online. Check these sites:

• Thingiverse – Popular free 3D model repository with section for action figures
• MyMiniFactory – Marketplace for miniature designs including articulated figures
• TurboSquid – 3D model marketplace with collectible category
• CGTrader – Diverse selection of 3D models including hobbyist designs
• Sketchfab – Models to browse and purchase with good categorization

Look through model collections for action figures, dolls, posable characters, and miniatures to find a suitable base model. Be sure to respect license terms.

Tips for Better 3D Action Figure Printing

To achieve great results 3D printing your own action figure, keep these tips in mind:

• Optimize positioning to minimize supports and overhangs
• Print in sections for easier assembly and more pose options
• Choose small layer heights for crisper details
• Use prime materials like PLA, resin, carbon fiber, or metal fills
• Sand and smooth parts before assembling
• Reinforce joints and connections with pins or glue
• Take special care painting faces and small details
• Capture personalities through fun poses and expressions
• Create custom bases or displays to show off your figure

With the right software, 3D printer, and design techniques, you can bring your ideas to life in detailed physical form. 3D printed action figures make great personalized gifts, collector’s pieces, and crowdfunding projects. Let your imagination run wild!