Darrell Maloney, aka The Damaged Nerd

As soon as in awhile, we get the prospect to satisfy and get to know a designer with severe expertise, and Darrell Maloney, aka The Damaged Nerd, suits that description to a tee!

Initially from New York, and now dwelling in Virginia Seaside along with his spouse and their two boys since 2001, Darrell is rising as a tremendous advocate and content material creator for 3D printing. As a graphic designer, Darrell had some expertise with artistic work. However after an harm in February 2017 that stored him out of labor, he watched a couple of DIY movies on YouTube about 3D printing by Uncle Jessy, and the remaining is historical past. He quickly purchased his first 3D printer and has been printing continuous ever since.

Darrell prints with a number of machines: the Creality CR-10, ATOM 2.5, Geetech A30, Robo R2, Dagamo and most not too long ago, the Peopoly Moai. At first, like so many different creators, he began with PLA however shortly moved to PETG after getting some superb outcomes.

One of many issues that set Darrell’s work aside is the time he takes in his post-processing to get really exceptional completed items. Darrell explains, “After I mannequin and 3D print my complete aim is when somebody sees the completed merchandise, that they can’t determine it as a 3D print. My publish course of approach is fairly simple. I begin with sanding, and if the merchandise has a big floor space I’ll apply Clean-On XTC-3D, then sand. I begin with 100 grit then step by step transfer to 2000 grit. I exploit a whole lot of primer filler and spot glazing putty to assist fill within the tremendous imperfections within the print with a view to obtain a clean floor. As soon as all the things is clean I’ll then transfer on to color and add electronics, and so on., relying on the construct.”

Being a graphic designer, Darrell is skilled in a number of software program platforms that assist him obtain his targets. At present, he makes use of Cinema 4D – which has some drawbacks resulting from its lack of functionality to make correct measurements – however he’s been utilizing it for about 4 years. He additionally makes use of Simplify 3D, Cura, and Mesh Mixer. He’s additionally beginning to learn to use Fusion 360 and ZBrush.

A newly sanded and primed Gazerbeam helmet from The Incredibles film.

Along with his expertise and persistence, Darrell has made a number of commissioned items for cosplayers and costumers many instances over. From Marvel Comics iconic items like Thor’s Hammer, Mjolnir, to his new Infinity Battle axe, Stormbreaker; in addition to the Infinity Gauntlet, gadgets from the DC Comics and Star Wars universes – a very massive vary of pursuits!

However realizing the method he makes use of doesn’t clarify why he takes the time to make such beautiful fashions and creations.

“3D printing in a way turned remedy for me. On the time once I purchased my first 3D printer my sister had handed away, and it was exhausting for me to cope with. I immersed myself in modeling, work, and 3D printing and I discovered that once I was engaged on ending an merchandise, I may course of my ideas and use that point to replicate. It aided within the therapeutic course of in a way. Lots of people complain about sanding however sanding turned (and nonetheless is) therapeutic for me.”

Designing the colour palette of the Nova helmet.

Regardless of this era of tragedy for Darrell, he continues to maneuver ahead in his work in modeling and 3D printing. “3D printing has lead me to locations I by no means thought I’d have the ability to go and meet folks I by no means thought I’d have the ability to meet. After I began 3D printing I had no intention of it going so far as it did. It lead me to create a Youtube channel, and from there I used to be capable of set up a working relationship with Make: and have produced movies for his or her platform. I’ve additionally had the chance to work with Examined.com on some superior collaboration tasks, and to not point out the excellent people within the 3D printing group like Uncle Jessy, James Print N Play, Kuntry 3D and extra! The 3D printing group is by far probably the most useful and accepting group.”

As a relative newcomer to the 3D printing group, Darrell sees room for enchancment in getting the 3D printing phrase out to a fair greater viewers, particularly at an academic degree.

Priming the Nova helmet earlier than the paint goes on.

“I hope to see 3D printers and the idea of 3D printing in additional numerous areas, as frequent because it is likely to be to people throughout the group, it’s nonetheless a comparatively new idea to lots of people. I discover myself greater than usually explaining the idea to folks and exhibiting them movies to assist them grasp what it’s and what it may possibly do. I feel what’s going to make 3D printing simpler and extra accessible is schooling and consciousness.”

Placing the ending touches on the Purple Hood helmet.

“There are superior folks like Josh from Design Make Train who exit and educate and are on the bottom flooring educating and bringing 3D printing consciousness to others. I’m nonetheless comparatively new, however as a result of there are such a lot of nice educators and people prepared to share their data that I used to be capable of get into it. Like them, I hope to encourage people to get into 3D printing and perhaps faucet right into a ability set they by no means knew that they had.”

After all, being a designer and having children, there are ardour tasks within the works. He’s within the strategy of designing a easy mannequin robotic package that his children can put collectively and play with.

Darrell has additionally develop into a full-fledged member of the Examined.com crew because the publication of this text – we will’t wait to see what he creates with the entire crew!

Darrell in his Knights of Ren helmet.

We look ahead to seeing extra of Darrell’s superb creations sooner or later – we will’t wait to see what he works on subsequent!

To see Darrell’s work as The Damaged Nerd, go to and subscribe to his channel right here: https://www.youtube.com/channel/UCRu7P5s0FToOgSIUkv7kOvg

To see his work with Adam Savage and the Examined.com crew, go to their channel right here: https://www.youtube.com/person/testedcom

Wish to be our subsequent Hacker of the Month? E mail chris.morgan@matterhackers.com, and inform us about your 3D printed creations – you can be featured in our subsequent publication. Hacker of the Month wins 3 free spools of PRO Collection PLA or ABS filament to additional their pursuit of 3D printing greatness!

Photos courtesy of Darrell Maloney and Make: – captured as screenshots from The Damaged Nerd YouTube channel.