Star Wars Imperial Flagpole

• Updated 25 November 2022 with new files and an additional flag topper for magnetic support for emblems.

Make your own Star Wars Imperial Flag Pole. very hand for parades or other Star Wars events where you might display a Star Wars or Costume Group flag.

My parts are printed in the following colors:

MatterHackers Silver Silk PLA:
https://www.matterhackers.com/store/l/silky-silver-mh-build-series-pla-filament-175mm-1kg/sk/M7X91KUX

ZYLtech Uncle Jessy's Gun Metal Silver Metallic PLA:
https://www.zyltech.com/metallic-pla-3d-printer-filament-1-75mm-1-kg-2-2-lbs/

These parts are designed to fit a stainless steel flagpole such as the one sold here:

https://www.homedepot.com/pep/DIIG-6-ft-Flagpole-Stainless-Steel-FlagPole-With-Mounting-Bracket-Adjustable-Length-DIIG6/319981566

All parts are in .3mf format compatible with most 3D slicing software like Ultimaker Cura.

There are a few parts to print and assemble:

• Emblem
  The top emblem consists of four parts: 2x 50 mm Cutout Imperial Cogs and a middle layer with the 50 mm Outer Ring and the 44.8 mm Inner Disc. This allows you to print the outer and inner rings as different colors. Glue the outer ring to the inner disc, and then glue and clamp the cutout cogs on either side. Total width is about 5 - 6 mm.

• Emblem Holder
  There are two version, one for 5mm emblem stacks and another for 6mm stacks, since printer variance can sometimes lead to thinner prints. If using a screw to secure the holder to the cap later, drill the hole to the desired diameter for your screw. For either magnet or screw method, glue the emblem stack into the holder.

• Flag Topper Cap:
  There are two versions of the topper caps:

"Flag Topper Cap magnet" is the NEW version that supports 12.5mm circular x 3mm neodymium magnets. Glue on inside the bottom of the cap, and another on the emblem holder.

"Flag Topper Cap screw" is the old version that uses a screw to secure the emblem holder to the cap. Screw the assembled emblem and emblem holder into the cog in the top of this piece, using a small wood screw through the bottom of the cap. Be sure not to use too long a screw. Drilling out the hole in the emblem keeper and cap may be necessary (the included hole acts as a pilot hole).

• End Cap: Glue this piece into the bottom end of the flag pole. It's decorative and keeps your hands or gloves form getting cut by the pole's often unburred end (sanding the edges of the pole end with 150 grit sandpaper can help with deburring also).

Flag Pole Prep:

With the recommended flag, you will need to temporarily remove the top bulb, cut off the top half of the bulb with a saw or Dremel, and sand flat and level (a belt sander is recommended). Afterwards, remove the flag mounts from the pole as well, spray paint the bulb and mounts with a metallic color that matches your PLA, and reinstall them.

Final Assembly:

Glue the assembled emblem, holder, and top cap to the flat end of the cut top bulb. I recommend a slight amount of E-6000 in case the cap needs to be removed if any parts need to be repaired or replaced.

Glue the end cap into the other end of the pole.

** COMPLETED **

Attributions:
Original Cutout Imperial Cog by BrieKalan2 on Thingiverse:
https://www.thingiverse.com/thing:2890903
All other parts designed by me using MS 3d Builder

Resolution: 0.2mm standard print

With above PLA, recommended settings:
Nozzle temp: 190C
Bed temp: 60C (BS glass)

100% infill for maximum strength.
Use a brim to prevent edge lifting during printing.
No supports required except for end cap.