Parts.

I acquired the following parts:

• One N20 6VDC 50RPM gear motor.
• One twin AAA switched battery box.
• Two AAA batteries.
• Six 3mm diameter by 1.75mm thick neodymium magnets.

I 3D printed the following parts at .15mm layer height, 20% infill, and no supports unless noted otherwise:

• One "Arm 1.stl".
• One "Arm 2.stl".
• One "Axle, Arm 1.stl".
• Two "Axle, Arm 2.stl".
• One "Base.stl".
• One "Cam.stl".
• One "Case.stl".
• Eleven "Charcoal.stl".
• One "Coupler.stl".
• One "Cover, Base.stl".
• One "Cover.stl".
• One "Rack.stl".
• One "Snowman, Arm, Left.stl".
• One "Snowman, Arm, Right.stl".
• One "Snowman, Base.stl".
• One "Snowman, Hat.stl".
• One "Snowman, Head, Mount.stl".
• One "Snowman, Head.stl".
• One "Snowman, Middle.stl".

This is a moderate precision 3D print and assembly model using at times very small precision 3D printed parts in very tight spaces. Prior to assembly, test fit and trim, file, sand, etc. all parts as necessary for smooth movement of moving surfaces, and tight fit for non moving surfaces. Depending on you printer, your printer settings and the colors you chose, more or less trimming, filing and/or sanding may be required. Carefully file all edges that contacted the build plate to make absolutely certain that all build plate "ooze" is removed and that all edges are smooth. I used small jewelers files and plenty of patience to perform this step.

The model also uses threaded assembly thus an M6 by 1 and M8 by 1.25 tap and die will assist with thread cleaning if necessary.

Snowman Assembly.

To assemble the snowman, I performed the following steps:

• Glued eight "Charcoal.stl" to "Snowman, Head.stl".
• Glued "Snowman, Hat.stl" to the head assembly.
• Glued "Snowman, Head, Mount.stl" to the rear of the head assembly.
• Glued three charcoal to "Snowman, Middle.stl".
• Glued "Snowman, Arm, Left.stl" to the middle assembly.
• Glued "Snowman, Arm, Right.stl" to the middle assembly.

Base Assembly.

To assemble the base, I performed the following steps:

• Glued "Coupler.stl" to "Base.stl".
• Turned the battery pack switch off, inserted two AAA batteries in the battery pack, then attached the battery pack to "Cover, Base.stl" using doubled sided tape, making certain the battery pack switch was accessible via the slot in the base cover.
• Routed the battery pack wires through the base assembly coupler.
• Snapped the cover assembly onto the base assembly.

Final Assembly.

For final assembly, I performed the following steps:

• Pressed three neodymium into "Cover, stl" such that the polarities matched.
• Pressed three neodymium into "Case.stl" such that the polarities matched and that the case magnets attracted the cover magnets.
• Threaded the battery pack wires into the case assembly, then glued the base assembly to the case assembly.
• Slid "Rack.stl" into the case assembly.
• Soldered the battery pack wires to the motor.
• Pressed "Cam.stl" onto the motor shaft then aligned the motor shaft flat vertically (this allows the cam to slip through the motor housing in the case assembly).
• Pressed the motor assembly into the case assembly until the cam aligned with the rack.
• Positioned "Snowman, Base.stl" onto the case assembly, positioned "Arm 1.stl" inside the case assembly with the pin in the arc in the case assembly, then secured in place with "Axle, Arm 1.stl".
• Glued the snowman middle assembly onto the arm 1 pin.
• Positioned the snowman head assembly in the vertical slot of the case assembly.
• Positioned "Arm 2.stl" over arm 1 and the head assembly, then secured in place with two "Axle, Arm 2.stl".
• Magnetically attached the cover assembly to the case assembly.

With assembly complete, I turned the battery switch on and the snowman commenced to dance!

And that is how I 3D printed and assembled "A 3D Printed Dancing Snowman".

I hope you enjoyed it!