On July 4, 2012, a groundbreaking moment in science was announced by researchers at the European Nuclear Research Center (CERN) through the Large Hadron Collider (LHC) project: the Higgs boson, often referred to as the "God particle," had been discovered! This elementary particle is crucial in modern theoretical physics, especially in explaining how other particles acquire mass. While the LHC itself is the world's largest and most powerful particle accelerator, its mission is just beginning, with countless experiments still to come.
At the heart of the LHC are two major particle detectors, with one being the Compact Muon Solenoid (CMS). The CMS plays a vital role in searching for extra dimensions and potential particles that could make up dark matter—mysteries that continue to puzzle scientists around the world.
Among the team working on the CMS experiment was James Wetzel, a Ph.D. from the Department of High Energy Physics at the University of Iowa. Wetzel has a passion for 3D modeling and CAD, and even owns a 3D printer. His interest in the project led him to create a 1:120 scale model of the CMS detector, designed to help explain the complex structure of the experiment to others.
"I made this model to give people a tangible sense of what the CMS looks like," Wetzel explained. "It’s much more effective than a digital representation because it allows people to see and understand the actual components in real life."
Using SolidWorks, he created a detailed model based on precise technical data from the experiment. Then, he used an Afinia H480 3D printer to bring the model to life. The Afinia H480 is a well-known 3D printer, often used by professionals and hobbyists alike, and it played a key role in this project.
The model consists of approximately 20 parts, with some sections requiring careful planning during the printing process. For example, the alternating blue and red end caps were printed separately, and Wetzel programmed the printer to pause at each color change. This allowed for seamless transitions between different colored layers, which took about 10–12 hours per model.
What started as a small personal project soon turned into a bigger challenge. After seeing the model, an outreach coordinator from Fermi National Accelerator Laboratory reached out and asked if Wetzel could produce 70 models for the CMS experiment, along with 20 additional ones for VIPs. Each model required around 50 hours of 3D printing time, making the task impossible for a single printer.
Faced with expensive quotes from professional companies—some as high as $130,000 or even $1 million—Wetzel decided to take matters into his own hands. He set up a mini-manufacturing station on his desk, using six Afinia H480 printers. With premium ABS filament, he carefully printed over 1,400 individual parts, assembling all 70 models. In total, the materials cost around $2,000—far less than the offers from companies.
After completing the order for Fermilab, Wetzel is now considering selling the models publicly, with a planned price of $275 each. His story shows how creativity, determination, and 3D printing can turn a small idea into something truly impactful.
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