400 kV High-Voltage Pylon Y25

This model is a detailed, scale reproduction of the Y25 single-circuit 400 kV high-voltage tension pylon, an essential component of high-voltage electrical grids.

The design is based on a precision 3D photogrammetry scan taken in the field using a RTK-equipped drone. The real-world pylon stands at approximately 29.8 meters (Y25 M3+5). To guarantee clean lines, optimal strength, and a hassle-free printing experience on FDM printers, the entire structure was remodeled from scratch in Blender, using the scan mesh purely as a dimensional reference.

Watch the full project video & assembly guide: 

Note: The video audio is in Polish, but auto-translated subtitles and YouTube AI English dubbing are available in the player settings!

Key Features & Design Highlights:

• Support-Free Optimization: The tower is split into flat-printed modules to eliminate ugly support marks on the thin lattice work. The only section requiring light support is the top peak section (Organic/Tree supports recommended).

• Tool-Free & Glue-Free Assembly: Integrated assembly pins and press-fit connectors allow the model to snap together securely without glue. (A drop of CA glue can be added to joints for permanent stability if handled frequently).

• Modular Construction: Includes base footings, structural body sections, crossarms, and attachable insulator strings.

Recommended Scales & Heights:

• H0 Scale (1:87): ~35 cm tall (Standard model train scale). Matches real-world ground clearance variations—includes an optional extension section for hilly terrain setups.

• Large Scale (1:75): (Tested on Prusa Core One / standard 250x250mm build plates).

• Compact Scale (1:109): Fits smaller build volumes using a standard 0.4 mm nozzle. Note: The insulators have not been test-printed at the smaller 1:109 scale. Due to the fine detail of these components, using a smaller nozzle (such as 0.2 mm) or resin 3D printing may be required for optimal results at this size.

Print Settings & Recommendations:

• All files have been fully test-printed and verified using the following configuration:

  • Tested Printer: Prusa Core One +

  • Nozzle Size: 0.4 mm (Standard)

  • Layer Height: 0.20 mm (BALANCED)

  • Infill: 15% (Rectilinear)

  • Profiles: Default PrusaSlicer profiles

  • Supports: Minimal supports required. Organic / Tree supports are mainly recommended for the top peak sections, alongside tiny custom/minimal supports in a few specific overhang spots.

  • Orientation & Layout: The top peak sections/towers are pre-oriented in the provided .3mf project files for the most optimal print quality and bridge stability.

  • Tested Materials:

    • PLA Prusament Gravity Grey (ideal for an authentic galvanized steel look), Prusament Army Green, Prusament Galaxy Black, Prusament Blood Red, Prusament PLA Galaxy Silver

How to Assemble the Y25 High-Voltage Pylon

Print Files Notice:

• .gcode / .bgcode files are pre-sliced specifically for Prusa Core One (using PLA / PETG).

• If you are using a different 3D printer, please use the provided .3mf or .stl files to slice the model for your machine setup.