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NOTE: This is really a "Make" post, but is posted as a "Remix" because I made minor changes to two parts and Thingiverse won't let me attach the revised STLs on a "Make" post. Only those (2) parts are included here. Please refer to the original thing for all other components.
This was a challenging project. The parts are large, with some taking 4-6 hours EACH to print. I used silver ABS for the structure, and white (Natural) HIPS for the lights. I initially tried transparent ABS for the lights, but had some significant problems with shrinkage causing the lowest ring of the light to be distorted during the print. Moving to the white HIPS mostly resolved that. I also tried transparent PETG, which printed perfectly, but did not like the "shiny" or "wet" appearance of the PETG for this project. The Natural HIPS does a good job of light transmission, and looks more authentic than the transparent ABS or PETG.
See it in action at: https://youtu.be/F7alNxlbV9E
I did a re-design to the warp core plug. The original was too small (gaps around it), and the brace that connects the two halves was too long which prevented it from being fully inserted into it's receptacle. So I made an new model that is larger, but with a shorter connecting brace. It is now just large enough that (with a little sanding) it is a press-fit and no glue is required.
I did a minor re-design to the core "window" lights (MARC_Lights). The original was narrow and left some gaps unless perfectly centered, and had to be glued in place (difficult when working on the inside the warp chamber, what with all that radiation). I made the lights taller to eliminate gaps, and added a "tab" at one end. The tab fits into the narrow opening of the MARC, closest to the Warp Plug. This allows the part to "snap in" tight, and no glue is required. These parts should be printed WITH SUPPORT (a very small amount at each end) due to the overhangs created by the width increase and added tab.
The big missing feature of the entire original design is some kind of mechanical alignment between major pieces, but I didn't attempt a redesign for that. All components just "stack" flush on top of one another, without any kind of tab/slot or post/hole features to stabilize or align the parts. I hope someone with the time and skill will consider redesigning the major pieces to have "holes" in the horizontal mating surfaces that match to the ends of the "post" support beams, allowing the whole assembly to fit together and self-align.
Thanks to the original designer, ThePlanetMike, for the idea and the time spent on the original design -- and for sharing with nerds of the world! :-)
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