Parametric Disc Golf Disc Designer

OnShape Link: Parametric Disc Golf Designer

Note: you will need to make a free OnShape account to customize this model. I don't know of a way to enable FeatureScript customization without it.

Background

I wanted 3D print my own disc golf discs using TPU, but I kept running into the same problem: supports made the prints messy, difficult, and inconsistent. fter doing some research, I found two awesome projects:

1. Ryan Marr's – Parametric Disc Golf Generator
This is a parametric OpenSCAD model of a disc golf disc, plus preset numbers for 28 famous PDGA-approved molds and a web-based designer.

2. Kitty Hawk's – Disc golf disc, no supports, floats in water
This disc requires no supports and has no overhangs. It is split into 4 parts and each one can be oriented where there are no overhangs or supports needed. The parts will need to be glued together.

Since Onshape is my main CAD and modeling tool, I used Codex to help adapt the code and profile-generation logic from Ryan Marr’s disc.scad file into an Onshape FeatureScript feature. I then added splitting logic inspired by Kitty Hawk’s Onshape model.

Now discs can be created, adjusted, visualized, and exported directly inside Onshape, making it much easier to tweak dimensions and experiment with different shapes. The feature also auto-magically splits the disc into four parts with flat surfaces, making the model easier to print without any support material.

Assembly, Weight, & Post-Process Tips

Summarized from Kitty Hawk's Post

I printed all the parts in TPU 95A, which gives it good durability. I would not recommend a hard filament because it will most likely crack.

The important part to get the weight correct is print the Top.stl, Bottom.stl, and Inner.stl files first, weigh them all, and then adjust the infill settings on Plate.stl to get the weight you want. I wanted around 170-175, and it ended up at 173g, which is basically perfect.

Some suggested settings:

Outer Rim - Upper: 

• Infill 35% gyroid

• 3+ walls

• 0.15mm layer height

Outer Rim - Lower:

• Infill 35% gyroid

• 3+ walls

• 0.15mm layer height

Inner Rim:

• Infill 30% gyroid

• 2 walls

• 0.2mm layer height

Top Plate:

• Infill 15-40% gyroid (depending on how dense the filament. Print all the other parts and adjust infill percentage until you get a good weight, around 173g for me)

• 2 walls

• 0.15mm layer height

Post processing tips:

• When you glue it together, put it on parchment paper so it does not stick.

• Use a deburring tool or a sharp knife to smooth down the inner rim, it can be pretty sharp otherwise.

• Use sandpaper to remove excess glue, it does not seem to be able to sand TPU very well.

Why the AI Tag

OpenAI Codex was used the convert OpenSCAD code to OnShape FeatureScript. But no AI was used to generate the models or images.