The goal for our group was to create a repeatable tile using the 3d printer. We decided to use a symmetrical tile pattern of three inches by three inches because of the size and cost of the printer bed. Using Rhino we began with surface manipulations to form the overall shape of the tile. Rather than being a flat pattern, we lifted opposite corners to create a wave-like texture. We then used Grasshopper to generate a wave-like fin pattern that would oscillate over the surface. This allowed us to view many options quickly and fine tune the pattern to how we wanted. We used the same definition in grasshopper to generate cut lines in the surface running in the transverse direction to fins. The final modification was to apply a gradient material to the main surface, transitioning from white to black. All of these techniques were to build depth into the pattern that we hoped would create interesting effects when mirrored and arrayed to make a surface.
Our first prototype was a simplified version of the final tile in which we were testing for material thickness and strength, and color quality. We used a vrml file type, but test loaded 3ds and stl files to check if they all loaded equally, which they did. We also noticed that the polygon count when saving to vrml will create a noticeable mesh pattern if the default is used. Through this process we learned that the fins could be much thinner as they are not the main structural elements and the overall height could be decreased slightly to increase production time.
The first prototype cost twenty dollars and was estimated to take roughly two and a half hours. We were not around when the print finished as we had to leave it overnight, but the computer said it finished close to the estimated time.
Project specs:
Size of panels: 3" x 3" individual (6" x 6" total)
materials: powder and glue
production time: 8 hours design / 2 hours production
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