Here's a nice little model I did of R2D2. He is split up into a lot of pieces, and they all fit together pretty snug. I ended up only having to glue the two body pieces and the "Stops". All the parts are meant to be printed, although some features might be too small.   
 I just eyeballed the dimensions so he would look right, and I also wasn't too concerned with making his features 100% accurate. Along these lines I renamed him R2B0 and gave him a nice orange color scheme in the model.   

enjoy :)

If you like any of my things, you should check out my website:
meanderinglaser.weebly.com

I'll post projects to be made with my small laser engraver, as well as plenty of other tidbits!

I just printed out all of the parts separately, and then sanded them down so they would fit into each other. The only pieces I needed to glue were the top and bottom half of the body and the stops to the middle leg.