Folding Performance Fan - Modular 3D Printed with TPU Feathers

Overview

This is a fully 3D printable folding performance fan designed for stage performances, cosplay, and theatrical productions. With a 25.5" wingspan when fully opened, this fan creates the same dramatic visual impact as traditional feather fans but with modern durability.

Unlike traditional feather fans, this design is durable and can handle the rigors of repeated performances without the delicate handling requirements of real feathers. The fan can be operated as a folding fan for dramatic reveals or locked in a fixed open position by tightening the center bolt.

What Makes This Special

The modular design lets you mix and match colors, combine printed feathers with real ones, or create unique effects with specialty filaments. The fan staves are designed to work like traditional fan staves, so you're not locked into using only 3D printed feathers - you can attach real or faux feathers with wire just like a standard fan.

Print Requirements

For One Complete Fan:

• 10× Fan Staves (rigid material)

• 30× Feather Clips (rigid material)

• 10× Complete feather sets (TPU)

• 1× Fan Thread (TPU) or use 1mm Waxed Polyester Cord (https://amzn.to/3Kt1Bil)

Materials:

• Staves and clips: PLA or PETG

• Feathers and thread: TPU (95A or softer recommended)

• Fans in photograph made with:

  • ELEGOO Rapid PETG (https://amzn.to/4aibkT7)

  • ZIRO TPU (https://amzn.to/3MyXWjx)

Hardware Required

• 1× M8 Bolt: Length should be 30-35mm for a 10-stave fan (10 staves × 2.6mm thickness + clearance for nut)

• 1× M8 Nut: Standard M8 nut to secure the bolt

• Optional: M8 washers for smoother pivoting action

Hardware Sources:

• Amazon: https://amzn.to/3YnNGND

• Printables:

  - Note: Metal hardware strongly recommended for durability. Printed bolts may fail at the layer lines under stress.

Print Settings

Fan Staves (332mm long):

• Layer Height: 0.2mm

• Infill: 10%

• Walls: 2-3 perimeters

• Important: Use a brim or raft to prevent warping on these long parts, especially with PETG

• If your bed is smaller than 332mm, print diagonally

• Print flat on the bed

Feather Components (TPU):

• Layer Height: 0.1mm

• Infill: 100%

• Print flat, no supports needed

• Standard (0.4mm) version: For regular performances

• Thick (0.8mm) version: Better layer adhesion for glow-in-the-dark or UV reactive TPU

Feather Clips:

• Layer Height: 0.2mm

• Infill: 100% for strength

• No supports required

Fan Thread (Optional):

• TPU only

• 100% infill

• The built-in beads maintain even spacing when the fan opens

Assembly Instructions

1. Prepare the Feathers: Attach feathers with 3 clips to each of the individual staves 

2. Stack the Staves: Align all 10 staves at the pivot point (the end with the hole).

3. Insert the Bolt: Thread the M8 bolt through all aligned pivot holes. Don't tighten completely yet.

4. Thread the Fan: If using the printed fan thread, pull it through the threading holes in each stave. If using regular thread, tie a knot at one end and weave through. The thread limits how far the fan opens and maintains even spacing.

5. Final Adjustment:

   • For a folding fan: Keep the bolt loose enough to allow smooth opening and closing

   • For a fixed display: Tighten the bolt to lock the fan in your desired position

Customization Options

Feather Variations:

• Use different colored TPU for each feather for an ombre effect

• Mix the standard and thick versions for texture variation

• The thick version is essential for specialty filaments (glow-in-the-dark, UV reactive) as it provides better effect visibility

Hybrid Designs:

• The staves accept traditional feather attachment methods

• Combine 3D printed and real feathers

• Use wire wrapping for additional decorative elements

Size Modifications:

• Design is optimized for 10 staves but can work with 8-12

• Adjust bolt length accordingly (2.6mm per stave for standard, 3.4mm per stave if using thick feathers)

Performance Notes

These fans are significantly more durable than traditional feather fans. They're spill-resistant and don't require the delicate handling of real feathers. The TPU feathers can be washed if needed and will spring back to shape.

The complete fan has a 640mm (25.5") diameter when fully opened, making it suitable for professional stage work. The feathers extend approximately 255mm beyond the pivot point when the fan is displayed.

Tips for Success

• Preventing Warping: The long staves are prone to warping. Use a brim, raft, or glue stick on the bed. PETG is particularly susceptible.

• Color Choices: Any color TPU works, but consider your lighting conditions. The thick feather version is specifically designed for special effect filaments that need more material to show their properties.

• Maintenance: TPU feathers can be cleaned with mild soap and water. If a feather gets bent, gentle heat (hair dryer) can help restore the shape.

• Transport: The folding design makes these easy to transport. Consider finding a simple sleeve or case to protect the feathers when packed.

Designer Notes

This design emerged from the need for durable, customizable performance fans that could withstand the demands of regular shows while maintaining the dramatic visual impact of traditional feather fans. The modular approach means you can replace individual components if damaged rather than the entire prop. It also means you have much more control over the look of your fans. As well, you can swap different fan parts without needing to invest in completely new fans!!!

Questions or modifications? Feel free to reach out through Printables comments. I'm always interested in seeing how these are used in performances!

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