After the rise of **3D printing technology**, more people are turning to custom-designed gifts to express their love in a unique and meaningful way. These personalized creations are not only trendy but also hold deep sentimental value, making them perfect for special occasions.
In a world where every father is considered "cool" in his own way, Australian maker Tez Gelmir took the concept of a "cool dad" to an entirely new level. For her daughter’s first birthday, a *Star Wars* enthusiast, she decided to build something truly unforgettable—a custom **Trojan** based on the iconic speeder bike from *Star Wars: The Return of the Jedi*, released in 1983.
This project was no small feat. It required a wide range of skills, including **3D modeling**, **3D printing**, woodworking, sewing, painting, and even electronic wiring. Gelmir spent several weeks printing the parts, with each piece taking around a dozen hours. She then cut and smoothed the plywood carefully to ensure it was safe for her baby. Fortunately, she documented the entire process on Instructables, a popular DIY platform.
Gelmir explained that the design was based on high-quality images she found online, which she scaled up and adjusted to fit the requirements of a toy. Her main goal was to make sure the toy was sturdy, stable, and safe—not just for her one-year-old daughter, but also for her five-year-old son, who would likely play with it often. To achieve this, she used reinforced **plywood** for the seat and made sure all parts were easy to assemble.
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The materials she chose were affordable and practical. She used **plywood** because it's cost-effective and easier to work with than regular wood. She also provided printable templates on Instructables, making it simple for others to replicate the design. For the round and small parts, she relied on **3D printing**, while PVC pipes and screws helped assemble everything together.
Gelmir printed the main components using a **Makerbot Replicator 2** 3D printer. To make painting easier, she set the print layer height to 0.3 mm and a fill rate of 10%. While most parts didn’t need support structures, the curved sections of the main hull required some extra support.
Once all the pieces were ready, she sanded them thoroughly, assembled the structure, and added multiple layers of paint. She even installed a real leather seat for comfort. The final touches included sound and light effects, as well as tiny details like power battery turbines, bringing the **Trojan** to life in a truly magical way.
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