What ever happened to the magnetic letters of my childhood??
Ohhhh they trigger proximity switches, a leapfrog sings the letter in a jingle now...
Or we can just learn the alphabet!?
Print the Alphabet and adhere a small piece of cuttable magnetic sheet to two sides of the print with hot melt glue in the cavity on the reverse and viola.
Prusa i3 mk2
At least .2 mm finer the better
Make sure to have the extrusion width as close to perfect as possible and there will not be a need for much post finishing.
Bright colors save a lot of finish time so print each set of letters in a new color for the kiddies enjoyment.
Layer height should be as low as possible because sterilizing fused filament is still an issue with items that will end up in kids mouths. Remember that banding is the nature of this production process which means germs have homes. Personally I print these at a .05mm layer thickness in ABS only and will sterilize them in the washing machine in a basket trap. ( ABS has a higher melting point thus can be brought closer to proper temperatures for sterilization later)
Step 1- ...
I use a flat mini file to remove the 3mm brim on each letter, and resurface the sides before I move to a 400 grit wet sandpaper to achieve a very slick surface finish.
I did not take pictures or video this process for the prototypes, as I only partly finished the correct size "A" as a proof of concept. Look for those in the near future with the actual prints in the coming weeks.