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3D Printing Fuels Innovation in Models and Toys: New Releases Including Estes Rocket Kits and Lego Trains

September 27, 2025 Applications 124

In recent years, 3D printing technology has been steadily permeating the model and toy sectors.

It not only offers enthusiasts greater customization possibilities but also enables traditional toy brands to achieve innovative breakthroughs. From DIY model rockets to Lego toys incorporating mass-produced 3D-printed components, various new products balance fun and creativity while making the "hands-on experience" more accessible than ever.

As a model manufacturer focused on the amateur hobbyist market, Estes Rockets has launched the Pro Series II Scorpio 3D model rocket kit. This product combines traditional physical rocket components with the flexibility of 3D printing, targeting intermediate rocket enthusiasts with some experience. Priced at $40, it offers outstanding value for money.

Core Configuration: Physical Components + Downloadable 3D Printing Files
Upon purchasing the kit, users receive the necessary physical parts for rocket assembly along with downloadable digital files for 3D printing. The files are provided in both imperial and metric versions to accommodate users with different preferences. These 3D printing files cover key rocket components: the nose cone, fin shroud, body tube connector, male and female engine retainers, and six different fin designs. Printing requires no special support structures (though users can add them if needed), and the files are compatible with common 3D printing materials such as PLA+, PETG, or ABS. Users can simply follow the general parameters provided with the kit to complete the printing on a home 3D printer.

Design Highlights: Tool-Free Fin Swapping for Aerodynamic Experiments
The core innovation of the Scorpio 3D lies in its twist-lock fin can system—fins can be replaced without any tools or glue, simply by twisting them on or off. Paired with the six included fin designs, users can immediately test different fin configurations or freely design and print their own. This transforms every launch into an "aerodynamics mini-experiment": by swapping fins, users can directly observe how fin shape affects altitude, stability, and flight path, blending hands-on fun with practical STEM learning.

Performance Specifications
Balancing flight performance and recovery safety, the Scorpio 3D offers the following specs:

Height: ~105.4 cm | Diameter: 2 inches (~5.1 cm) | Weight: ~482 g

Recovery: Includes a 24-inch (~61 cm) tear-resistant parachute for safe return after launch

Engine Compatibility: Supports E16-4 and F15-6 model rocket engines, reaching altitudes up to ~304 meters

Launch Options: Compatible with a 0.6 cm launch rod or 1010-style rail, adaptable to Estes Pro Series II launch pads or rails

In addition to the 3D-printed parts and digital files, the kit includes all necessary physical assembly components: body tubes, engine mount tubes, high-strength Kevlar® cord (for parachute attachment), shock cords, and water-slide decals for customization. Combining these physical parts with the 3D-printed elements results in a fully functional, ready-to-assemble rocket.

3D Printing Guidelines and Considerations

To help users produce qualified components, Estes provides specific parameter recommendations:

Wall thickness: Set to approximately 0.6-0.8 mm.

Nozzle diameter: 0.4 mm recommended (standard for most home 3D printers).

Infill pattern and density: Gyroid infill at 7% (balances strength and lightweight requirements).

Brim width: 3 mm or wider to ensure the part adheres firmly to the print bed and prevents shifting during printing.

For printing the critical nose cone component: If the user's home 3D printer has a build height of at least 260 mm, the nose cone can be printed as a single, integrated piece. If the printer's build volume is insufficient, the nose cone model can be split into multiple sections for printing and later assembled using adhesive. However, this segmented approach demands higher precision during assembly and greater modeling experience to achieve a clean, seamless final result.

Please note: The kit itself does not include a 3D printer. Additionally, launch equipment (such as a launch pad), igniters, and rocket engines must be purchased separately by the user.

3D Printing Expands Toy Innovation: LEGO and Enable 3D Make Breakthroughs

Beyond model rockets, 3D printing is seeing increasingly widespread application within the toy industry. It enables users to customize unique toys, repair old ones, and develop creativity and hands-on skills through the making process—all at a relatively manageable cost. The experience of "creating" often proves just as rewarding as the final toy itself. Recently, several brands have launched new products incorporating 3D printing technology:

LEGO's First Mass-Produced 3D-Printed Component Toy: Icons Holiday Express

The renowned Danish toy company, the LEGO Group, has released the LEGO Icons Holiday Express set. This marks LEGO's first toy to include mass-produced 3D-printed components. The set consists of 956 pieces and focuses on a festive holiday decoration theme. The functional parts within the train (such as certain drive or connection mechanisms) are manufactured using EOS systems. This process employs ultra-precise CO₂ laser technology to achieve high-detail accuracy while strictly maintaining LEGO's iconic standard connectors, ensuring full compatibility with other LEGO bricks.

3D-Printed Parts in the LEGO Holiday Express

The set also includes a circular track made of 16 bricks, which can be displayed on a tabletop or wrapped around a Christmas tree, creating a strong festive atmosphere. According to information obtained by Polar Bear (南极熊), this set will be available for sale to LEGO Insiders members starting October 1, 2025, and will be released to the general public on October 4, 2025. The price is set at $129.99 (approximately €119.99).

Enable 3D Partners with Selber Machen: "Print-and-Play" Toy Tools Made from Recycled Materials

The German online platform Enable 3D has partnered with the DIY magazine Selber Machen ("Make It Yourself") to launch a series of "print-and-play" toy tool kits. These kits are specifically designed for 3D printing using recycled PETG filament (rPETG), transforming the printing process itself into a playful activity. For example, one kit allows children to print components like wrenches and gears, which can then be assembled into a functional toy crane. This approach not only demonstrates practical applications of 3D printing and circular economy principles but also makes the entire process—from printing to assembly and finally to play—a cohesive and educational creative experience.

Enable 3D Wins German Innovation Gold Award from German Design Council

Frankfurt-based startup Enable 3D, in collaboration with German DIY magazine Selber Machen (meaning "Do It Yourself"), has launched the "Print and Play Construction Company" series of toys. The standout feature of this series is its use of eco-friendly recycled materials. Developed by Amsterdam-based startup Reflow, the filament is made from recycled food packaging and is available in translucent colors—combining sustainability with visual appeal to meet children's desire for aesthetically pleasing toys.

Users can simply download free templates online or from 3D printing platforms and produce the toys using a standard home 3D printer. The initial product release includes eight toy tools, specially designed for children aged 2 to 6. The toys were developed and tested under the guidance of construction expert Stephanie Stefan to ensure safety and playability. Parents can also join in the fun, experiencing together with their children the joy of "printing toys and assembling them by hand."