Physical Builds

3D Printed GLaDOS

A completed 3D printing project where I rebuilt, optimized, and printed a scaled physical version of GLaDOS from Portal 2.

Blender render of the optimized GLaDOS model
The optimized GLaDOS model, rebuilt in Blender to be printable.
The project

From a video game to my ceiling

This project was a large 3D printed model inspired by GLaDOS from Portal 2. The goal was to take the GLaDOS design and turn it into a real physical object that could be printed, assembled, painted, and displayed.

I originally experimented with the idea using cardboard while living in residence during my second year at Western. Later, after getting a 3D printer, I returned to the project and rebuilt it properly as a full 3D printed model.

I consider the project complete because the model was fully optimized, printed, assembled, painted, mounted, and documented. In the future, I could revisit the idea by adding motors, movement, or voice interaction, but the finished project is currently focused on the completed physical build.

The finished model

Click the photo to view it full size.

Modeling and printing

About 50 hours just to make it printable

I found a 3D model based on the in-game GLaDOS design, but it was not ready for 3D printing. I spent around 50 hours repairing geometry, cleaning up vertices, simplifying sections, separating parts, and preparing the model so it could be printed in individual pieces.

The final model was split into smaller components and printed using my Ender 3 V3 KE with black and white PLA. I tried to make the parts as support-free as possible, with the head being the main exception. The full print took many weeks, with the longest single part taking around 20 hours to print.

The printed version helped prove out the physical design and gave me a much better understanding of what would be needed if I ever wanted to create a moving version in the future.

Cardboard, parts, and a moving head

Where it started, how it was printed, and a demo of the head movement concept. Click any image to enlarge.

Technical Details

A quick breakdown of the modeling, printing, and possible future additions behind the project.

Model Preparation

The digital model was cleaned and modified in Blender, with around 50 hours spent repairing vertices, simplifying geometry, and making the parts printable.

Printing Setup

Printed on an Ender 3 V3 KE using black and white PLA. The material cost was around $70, and the largest part took roughly 20 hours to print.

Possible Future Version

A future version could add head movement, motors, lighting, sound, or simple voice interaction to make the display more interactive.

What I Learned

This project gave me a lot more experience with 3D model repair, print planning, part separation, and working around the limits of a real 3D printer. It also taught me how much preparation matters before sending a large model to print.

I also learned more about designing for assembly. A digital model can look great on screen, but once it has to be printed, connected, supported, and mounted, the design has to be much more practical.

Looking Back

This is still one of my favourite personal projects. I'm really happy with how the physical model turned out and how much work went into making it printable.

I consider the project complete as a 3D printed model, while still leaving room for a possible future version with movement, sound, or voice interaction.