Key Takeaways
- A full‑scale Star Wars: Andor control panel can be fabricated on a desktop FDM printer in under 30 hours.
- PETG (rated 85 % infill) offers the best balance of strength, surface finish, and post‑print machining for functional props.
- Layer height of 0.15 mm and a nozzle diameter of 0.4 mm keep tolerances within ±0.2 mm, sufficient for snap‑fit buttons and LED mounts.
- Compared with SLA and SLS, FDM delivers the lowest material cost (≈ $12 per panel) while meeting visual fidelity required for cosplay or display.
Overview
Will Muto, senior model‑maker at Industrial Light & Magic (ILM), recently demonstrated a step‑by‑step workflow for reproducing the iconic control panel seen in Star Wars: Andor. The project combines high‑resolution 3D modeling, desktop fused‑deposition modeling (FDM), and selective post‑processing to yield a functional prop that can be wired to lights, sound modules, or Arduino controllers.
1. Designing the Panel
1.1. Reference Acquisition
Muto began by extracting high‑definition screenshots from the series and overlaying them onto a CAD sketch. Critical dimensions—panel width 340 mm, height 210 mm, and button spacing 12 mm—were measured using the on‑screen ruler tool in DaVinci Resolve.
1.2. CAD Modeling
The geometry was built in Fusion 360, employing a modular approach:
- Base plate (5 mm thick) with reinforced ribs every 50 mm.
- Button housings (cylindrical, Ø 8 mm, depth 6 mm).
- LED recesses (Ø 5 mm, 2 mm deep) for future lighting.
Exported STL files were inspected with Meshmixer to close any non‑manifold edges and to add a 0.8 mm chamfer around all external edges, reducing post‑print sanding.
2. Selecting the Printing Technology
| Technology | Typical Layer Height | Material Cost (USD) | Build Volume (mm) | Surface Finish | Recommended for |
|---|---|---|---|---|---|
| FDM (PETG) | 0.15 mm | $12 per panel | 300 × 300 × 400 | Slightly visible lines; easy sanding | Functional props, high‑strength parts |
| SLA (Resin) | 0.05 mm | $30 per panel | 120 × 120 × 150 | Mirror‑like; requires extensive curing | Ultra‑fine visual detail, small parts |
| SLS (Nylon) | 0.10 mm | $45 per panel | 200 × 200 × 200 | No support structures; porous surface | Complex geometries, high durability |
Source: Manufacturer datasheets (Prusa, Formlabs, EOS) and Make: Magazine (2026).
Muto chose FDM with PETG because the panel’s size exceeds most SLA build envelopes, while the required strength for button actuation exceeds typical resin brittleness. PETG’s glass transition temperature (≈ 80 °C) also tolerates LED heating.
3. Printing Parameters
| Parameter | Setting |
|---|---|
| Printer | Prusa i3 MK4 (dual‑extruder) |
| Nozzle | 0.4 mm brass |
| Layer Height | 0.15 mm |
| Infill | 85 % cubic |
| Print Speed | 45 mm/s |
| Supports | Grid, 0.2 mm Z‑offset |
| Bed Temperature | 75 °C |
| Extruder Temperature | 240 °C |
The high infill density ensures that the panel can withstand repeated button presses without flexing more than 0.3 mm under a 2 N load (tested on a digital force gauge).
4. Post‑Processing Workflow
- Support Removal – Pliers and a 0.8 mm deburring tool.
- Sanding – 200‑grit followed by 400‑grit to eliminate layer lines.
- Priming – A thin coat of Rust‑oleum 7700 primer (dry time 15 min).
- Painting – Two coats of matte black acrylic, then selective metallic highlights using an airbrush.
- Electronics Integration – Pre‑drilled LED holes accept 5 mm diffusers; wiring is routed through internal channels designed in the CAD model.
Total post‑processing time averages 6 hours, including drying periods.
5. Functional Testing
After assembly, the panel was wired to a WS2812B LED strip and an Arduino Nano. A custom Arduino sketch toggles individual LEDs when the corresponding button is pressed, replicating the on‑screen effect from Andor. Latency measured at 12 ms from button actuation to LED response, well within the perceptual threshold for interactive props.
Bottom Line
By leveraging a desktop FDM printer, PETG filament, and a disciplined post‑processing routine, makers can reproduce a full‑scale Star Wars: Andor control panel for roughly $12 in material costs and 30 hours of print time. The workflow balances cost, durability, and visual fidelity, making it an ideal template for other cinematic prop reproductions.