Posable Rocky with Adjusted Joints (Project Hail Mary)

Disclaimer: I have only tested this design once! I'm not sure how this print will perform at different sizes from what I used.

The key print settings I used were:
-125% size
-PETG
-Organic supports, manually placed
-0.4mm nozzle
-0.1mm layer height

Like a lot of us, I printed that posable Rocky stl. But the design of his joints are less than ideal for fdm printers, requiring a lot of extra supports and post-processing.

I wanted a less painful process. So I remodeled several of Rocky's joints for ease of printing and fitting, namely by removing the horizontal 'split' from several of the pegs and balls, leaving only the vertical. I also added little flanges to the peg joints for extra hold in their sockets once assembled, and bulked up the hinge on a couple of his elbows for better grip to help him hold a pose.

-In PrusaSlicer, I used the 'add a part' workaround to get the legs to hover off the surface of the bed so I could get supports underneath.
-If you're worried about strength, you could add some more perimeters or infill, but for me it wasn't necessary.
-The better your printer does on overhangs and bridges, the better the joints will fit together.

Have fun!

May 16th, 2026
Made a couple edits based on feedback for Leg #4. Added a flat to the 4B hinge, and slightly expanded the 4A shoulder socket. I haven't personally test printed the changes, but if Leg #4 is giving you trouble and you want to try them, they're labeled as "alternate" 4A/4B/All Parts in the model files.

May 19th, 2026
Slightly (SLIGHTLY!!) reduced 4A Alternate shoulder socket size.