The design on the left is more accurate in regards to the rubber bands, but the design on the right is more optimized for 3D-Printing

The original plan for 3d printing the TPU object did not go to plan. The extruder wasn't hot enough, causing a jam, and more than four iterations of the Gcode were made to try and fix various issues. The current version is very stringy because of the high temperature, but we'll see how it cleans up with wire cutters.

The completed print was very stringy and attached very solidly to the build plate. It took so much force to get off that it ripped off the top coating (I'm very sorry about that).  The entire class period was spend trying to remove it from the build plate, and after that, removing the build plate from it.

I forgot to take a picture before taking off the supports, but I used flush cutters and an Exacto knife. This was printed on a Prusa, in TPU. The bed was 60 degrees (I think). We increased the temperature because the extruder was jammed and we thought that too low of a temperature was the issue. In hindsight, it wasn't, so that led to us printing it at too high of a temperature (240 celsius). This lead to stringing and too much adhesion to the build plate (mentioned earlier). We used Simplify 3D to make the supports easier to remove, but it was still really difficult. This was supposed to satisfy the "lightest object made of TPU" category. Though it was made with 20% grid infill, and that definitely isn't the lightest in terms of infill, the big base made it hard to do anything less to prevent it from sagging. So, it was the lightest possible to make.

We used Generic Black PLA for the structure itself and dissolvable PVA for the supports because of the especially intricate design.We used Turtle and had 20% infill (though at this scale it was probably inconsequential). The biggest challenge was finding a size that would print quickly enough but also have enough detail to really reflect Vaughn's original form.