World Darts Trophy

This model is my replica 3D Printed World Darts Trophy, inspired by Luke Humphries World Championship Darts Trophy 2024.

The Trophy is designed to be 3D printed in 3 parts which screw together and can be glued for permanent assembly. The base of the trophy is hollow which is designed to be filled with fine sand before final assembly, this will give the trophy some weight. Printing in multiple parts will mean you can print this on a small 3D printer such as the Prusa Mini. It also allows you to easily print in different colours for the base and upper parts. Personalising the blank trophy plates for your own text is a bit more complex, but achievable if you can learn how to print multi colour with a single extruder and some techniques applied to the Prusa Slicer. I have provided some links to videos on how to do this which I learnt from myself.

The Darts Trophy is printed in 3 main parts, with an additional 4 blank panels which can be customised with your own text before glueing to the base during final assembly.

1 - Base of Trophy - 6hrs 24mins
2 - Middle Upright Section - 12hrs 26mins
3 - The Globe Section - 7hrs 36mins
4 - 4x Blank Trophy Plates for Customising Text - 1hr 10mins

Dimensions -
Base Part = Width/Depth 77mm, Height 60mm.
Middle Upright Part = Width/Depth 90mm, Height 166.10mm.
Globe Part = Width/Depth 74mm, Height 106.5mm.
Fully Assembled = Width/Depth 90mm, Height 266mm.

Weight:-
267 grams without sand filled base.
455 grams with sand filled base.

Print settings for each part below. My settings are from Prusa Slicer, but you should be able to find similar settings in your favourite slicer software. I have optimised these for a balance of strength and quicker print times. You can increase decrease the settings to make a stronger trophy, but it will result in longer print times of course!

Base of Trophy - Print Settings

Part = DartTrophy_Base.stl
Layer height 0.2mm
x7 Permitters/Walls
x6 Solid Top Layers
x6 Solid Bottom Layers
Infill 15% Gyroid (The base is hollow, so if the settings above are applied, no infill will be needed)

See DartTrophy_Base_Prusai3Mk3.3mf project slicer file with the settings I used.

Middle Upright Section - Print Settings

Part = DartTrophy_Middle_Uprights.stl
Layer Height 0.3mm (I added a modifier cylinder over the central thread section and applied 0.2mm layer height for stronger thread)
x7 Permitters/Walls
x5 Solid Top Layers
x4 Solid Bottom Layers
Infill 15% Gyroid (I added a modifier cylinder over the central thread section and applied 30% infill for stronger thread)
Fuzzy Skin(Optional) -
IMPORTANT - I only applied fuzzy skin to the 6 outer uprights, not the centre upright as it has a thread the globe section needs to screw to!

To do this I applied fuzzy skin to the whole model and added a part modifier to the areas I don’t want the fuzzy skin applied where I disabled Fuzzy Skin.

Fuzzy Skin settings are - Skin Thickness 0.15mm & Skin Point Distance =0.8mm

See DartTrophy_Uprights_Prusai3Mk3.3mf project slicer file with the settings I used.

The Globe Section - Print Settings

Part = DartTrophy_Globe_Sphere.stl
Layer Height 0.1mm (I added a layer height range modifier over the stem under the globe and applied 0.2mm layer height for quicker printing the stem)
x4 Permitters/Walls
x5 Solid Top Layers
x4 Solid Bottom Layers
Infill 15% Gyroid
Brim - Inner and Outer Brim Width 10mm & gap separation 0.1mm
NOTE - I had adhesion issues on my textured bed, even with Brim. I swapped to non textured steel sheet and this had better adhesion.

See DartTrophy_Globe_Prusai3Mk3.3mf project slicer file with the settings I used.

Blank Trophy Plates - Print Settings

Part = Blank_Plate.stl
Layer Height 0.2mm (I added a layer height range modifier over the stem under the globe and applied 0.2mm layer height for quicker printing the stem)
X2 Permitters/Walls
x5 Solid Top Layers
x4 Solid Bottom Layers
Infill 15% Gyroid

See DartTrophy_PlaquePlates_Prusai3Mk3.3mf project slicer file with the settings I used.

Customising your own text/logos on the trophy plates

As you can see from the photos, I have printed my blank trophy plates with “WORLD DARTS” and an image of a dartboard(DartBoard.stl image included in STL files). This can be done in Prusa Slicer by loading in the blank trophy plate and merging TEXT or any STL object. I won’t go into detail here to explain how rot do it, you will have to research this yourself if you want to customise the plates. I have provided some links below to a few videos and settings from a forum on how best to do this:-

https://forum.prusa3d.com/forum/prusaslicer/manual-multicolor/paged/5/#post-664418

https://www.youtube.com/watch?v=t8PpQtInVhE
https://www.youtube.com/watch?v=_chI2WATVKg&t=480s

Multi-Extruders - I tricked my Prusa i3Mk3 into thinking I have a multiple extruder printer (using techniques in the links above). I printed my trophy plates on a Prusa i3Mk3, this has a bit more functionality in the slicer software such as a wipe tower between filament changes, so easier to trick. The wipe tower isn’t available on a Prusa MINI as it’s not designed to have multiple extruders, but you may be able to get away without a wipe tower with some trial and error. If multi colour is an issue, you could consider embossing text onto the trophy plates instead to personalise them.

I would advise using PETG for the print material as its less prone to warping if you leave your trophy in direct sunlight on a windowsill! Otherwise PLA will work fine for a shaded area in your house :-)