brettle / flexagon Goto Github PK

Using two solid fill layers on top of the 10% infill results in a fairly rough surface which make it difficult for the triangles to lay flat on each other during a fold. Options include higher infill percentage and/or more solid fill roof layers, both of which will increase print time.

The corners aren't too difficult to get up with a fingernail, but the edges under the circle are very challenging and there is a risk of breaking the triangle while removing it. Adding a small lip to the edge would probably be sufficient. Note that the lip should not be included where the slot meets the edge (i.e. where the rubber band comes out) because that would cause the rubber band to squish the paper during folding. Three lips along each edge (one between the slots, and one at end) would probably work well.

Add slots on the edge of the edges of the triangle to accomodate tabs on the pictures. The tabs would be folded back and inserted into the slots to keep the picture stationary.

To reduce print time, try reducing the triangle and circle slots to just outlines so the most the triangle is empty space. It's not clear how much material needs to remain for the triangle to be rigid enough for use.

The current triangles are 104mm on a side, so only 3 of them will lay flat on the Rep 2 print bed side-by-side. Options for printing more at a time include:

• Print them on edge. There are at least three potential problems with this approach. First, since the width of the extruded filament is 0.4 mm, presumably the ridge thickness would also need to increase to at least 0.4 mm from it's current 0.2 mm (resulting in even thicker triangles). Second, it's not clear whether the triangles would stay upright during the printing process. They might require some sort of support structure which could be difficult to remove. Third, the triangles were designed to be printed flat without supports, and that design would require supports (withing the triangle) if the triangle was printed on edge.
• Print stacks. Some sort of support/raft would be required between the triangles, and it's not clear how hard that would be to remove or the effect it would have on the smoothness of the side surface. Use a printer with dual extruders and printing the support in dissolvable filament should address this.

Currently leaning toward printing stacks.