Summary

Mr. Huffle feels pain!

Actually, probably not. And he doesn't squeak either. But, at least you can have him now.

Based on the prop from the 2016 Doctor Who Christmas Special.

Can print without support, however the bottom of the eyes and lips will likely require some cleanup, depending on your printer.

The ears print separately, and key into the head. You may need to sand the keys just a little, but they are meant to fit fairly tight. Recommend printing the ears fairly solid.

Print Settings

Printer Brand:

FlashForge

                                            <p class="detail-setting printer"><strong>Printer: </strong>                     <div><p>FlashForge Creator Pro</p></div></p>                                                                                <p class="detail-setting rafts"><strong>Rafts: </strong>                     <div><p>Doesn't Matter</p></div></p>                                                                                <p class="detail-setting supports"><strong>Supports: </strong>                     <div><p>Yes</p></div></p>                                                                                <p class="detail-setting resolution"><strong>Resolution: </strong>                     <div><p>.2 mm for body /  .1mm for ears</p></div></p>                                                                                <p class="detail-setting infill"><strong>Infill: </strong>                     <div><p>10% body / 50 - 100% for ears</p></div></p>                                                        <br>                        <p class="detail-setting notes"><strong>Notes: </strong>                    </p><div><p>Printed here with ABS.</p><p>I used rafts, as ABS simply will not stick to my platform, even using Kapton Tape.  But if you don't have that issue, you're better off without.</p><p>I recommend bumping up the shell thickness just a little.</p><p>For the ears, you MUST generate supports, due to the key, which will hold them to the body later.  I chose to print them solid, but probably not entirely necessary.  </p><p>For the body, Simplify 3D generated supports for the mouth, but not the eyes and I didn't find them to help much...actually would have preferred better support under the eyes.  Also, the supports it generated for the bottom chamfer didn't do much either.  So, my takeaway-- supports won't hurt, but won't help much either.</p></div>

Post-Printing

Clean up the face and body as necessary.

Sand the keys on the ears, and insert into the head.

Optionally coat with something like XTC-3D, sand, and paint.

How I Designed This

Modeled in Rhino, based on the sketch posted by @doctorwho_bbca.