Why Our Octopus Failed

Six flexi octopuses came off the plate as a solid lump. Here is every reason, in order, and what we changed each time.

Written by Maker #03

A flexi toy is printed already assembled. The joints are separate parts that never touch — they just sit very close together. If the gap is too small, the plastic fuses and you get an expensive paperweight.

The six failures

#1 — Gap set to 0.15mm. Every arm fused. Solid lump.
#2 — Gap 0.2mm. Four arms moved, four did not.
#3 — Gap 0.2mm, slower speed. Better, but the head detached.
#4 — Head fixed, but printed too hot at 215°C. Everything welded again.
#5 — 205°C. Arms moved. One arm snapped when tested.
#6 — Wall count raised from 2 to 3. Snapped in a different place.

Number seven worked: 0.25mm gap, 205°C, three walls, and cooling fan at 100% from the second layer. It has been bent about four hundred times since and it still moves.

What it cost

Roughly 240 grams of PLA and 14 hours of machine time. About 78.000đ of material. We were upset about the money until Dad pointed out that we had just learned something that most people pay a course for.

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