3D CAD designer needed– One-Piece Faux Leaded Stained Glass Frame (PLA, Epoxy Fill)

Project Overview

I am building stained-glass-style windows for a charitable memorial installation. For safety and durability, I am not using real lead or glass. Instead, I want to 3D-print a highly accurate replica of traditional lead came, which will later be filled with epoxy resin to simulate glass.

The goal is for the finished piece to be visually indistinguishable from real leaded stained glass, while being lightweight, safe, and suitable for outdoor use.

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Key Design Requirements

Overall Construction
• The lead frame must be designed to be 3D-printed as one piece, or at most two pieces, which can be glued together for added rigidity and strength.
• The design should avoid small modular segments or puzzle-style assembly.
• Final assembly must be flat, rigid, and dimensionally stable for epoxy pouring.

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Interior Lead Came (Simulated Round H Came)
• Must accurately replicate ¼″ Round H lead came:
• Face width: ¼″
• Internal channel (glass channel): 13⁄64″
• True H-profile is required so epoxy resin is mechanically trapped on both sides, exactly as glass would be in real lead came.
• Rounded exterior profile consistent with traditional round lead
• Slight irregularities and imperfections are welcome to simulate handmade lead work

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Perimeter Lead Came
• Flat channel profile (C / U shape)
• Channel width and face width must visually match ¼″ Round H came
• Designed to trap epoxy at the outer edges of the window
• No exposed resin edges once filled

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Aesthetic Requirements

The printed lead must convincingly simulate real lead came, including:
• Correct depth and proportions
• Rounded edges
• Subtle surface texture
• Simulated solder seams, joints, and small imperfections
• Matte, aged-lead appearance (post-processing or paint is acceptable)

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Workflow
1. I will provide:
• Hand sketches or drawings of the window layout
• Overall dimensions
. Photos of real leaded glass windows for simulation details
2. You will:
• Create accurate CAD models of the lead came profiles
• Convert the window design into print-ready STL files
• Ensure internal channels are suitable for epoxy resin fill
• Optimize for PLA printing
• Print prototype to test file accuracy and modify design as needed.
3. I will:
• Print the final parts using a third party if you cannot do this for me.
• Glue assemblies if required
• Fill the openings with epoxy resin to simulate glass

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Deliverables
• STL files (print-ready)
• Optional: STEP, Fusion 360, or SolidWorks source files
• Printing and assembly recommendations (orientation, tolerances, glue)
• 3D print up to three prototypes for proof of concept and testing
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Required Skills
• 3D CAD design (Fusion 360, SolidWorks, Blender, etc.)
• Experience designing parts with internal channels or cavities
• Familiarity with 3D printing constraints (PLA preferred)
• Strong attention to dimensional accuracy and craft detail

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Budget & Project Context

This is a charitable / memorial project, not commercial production.
I am looking for a designer who can work efficiently and at a reasonable cost.
Public credit for the design work can be provided if desired.sed payment schedule bad deliverables are provided.

All work produced under this project shall be considered a work-for-hire. The client retains full ownership of all CAD, STL, and derivative files. The designer may reference the project in a portfolio on a non-exclusive basis but may not resell or reuse the designs without written permission.

The attached are for discussion only. This is not the art work that will be provided.