I’ve been working a my 3d printed dome for BB8 for a while and I’ve been trying to find way to make it lighter. A few weekends ago I decided to try vacuum forming my printed dome and to my surprise it actually worked. I then tweaked my settings a few times to get the optimal look. The pictures below are versions 1.0 and 2.0 next to the original 3d version. I’m impressed not only that it worked but also by the amount of weight I’ve saved. It now only weighs about a 3rd of the original 3d version. At present I’m painting and installing the lights so I’m saving the final picture of the completed dome for a few more days. I’ve also stumbled over a way to save on lighting weight as well which I’ll show at a later date. My present dome I’m working on will do full revolutions meaning the entire dome and skirt will spin together. I’m also working on a 3rd dome version where the “skirt” doesn’t turn at all, just the dome itself will turn. This is the way the original BB-8 in the movie works. I should also note that the internal mechanisms are already installed and setup to work that way.
A minor update but a big difference