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We've completed our yearlong print-a-day project!
All new material is now at Hacktastic: www.mathgrrl.com


Wednesday, April 9, 2014

Day 226 - Tetris box puzzle

RarelyEvil's 3D Tetris Pieces Puzzle with Box on Thingiverse is one of the nicest working models I have seen on Thingiverse. It's a simple thing - just 3D Tetris-like pieces that fit together into a rectangular shape inside a box. But the details of this model are impeccable. First of all, the pieces consist of one of each of the eight tetracubes, which is very cool. Second, they fit into a 4x4x2 box exactly (math geeks study stuff like that; for example, see bumblebeagle.org for ways to pack pentacubes and hexacubes into a 5x5x2 box). Third, the pieces are very nicely rounded and print perfectly, and the box and its top are exactly the right size. This is one of those things that is just nice to play with; everything fits well together and the pieces make nice noises when they hit each other and the world is a good place. A great model for a gift if you're looking for one.


Thingiverse link: http://www.thingiverse.com/make:73669

Settings: MakerWare .3mm/low on a Replicator 2, using their fantastic Neon Green PLA filament for the pieces and white filament for the box.

Shameless elf-promotional note: If you like polycubes then you might also like polyominos; our newest Brainfreeze Puzzles book Double Trouble Sudoku uses tetromino and pentomino regions and is now available for pre-order and will ship in June!

Tuesday, April 8, 2014

Day 225 - Hilbert cubes

Today's print is sushiyaki's Hilbert block model on Thingiverse. This model is great because it prints without any supports at all, and some of the gaps between the paths even separate. There is also a natural slot that you can use to hold a business card or photo!


Thingiverse link: http://www.thingiverse.com/make:73667

Settings: MakerWare .3mm/low on a Replicator 2.

Stuff for the future: Bill Owens (owens on Thingiverse) has been thinking about making a Hilbert cube model that prints on its corner without the need for supports... stay tuned?

Monday, April 7, 2014

Day 224 - Rattlebacks

Today we printed VeryWetPaint's Rattleback Twins model from Thingiverse. If you spin one of these "rattleback tops" in the proper direction, it will actually shake and reverse itself, ultimately spinning in the opposite direction! It is really weird.


Thingiverse link: http://www.thingiverse.com/make:73666

Settings: MakerWare .3mm/low with the usual 10% infill.  We also made a set with a much higher infill but they actually worked less well than the 10% infill models.

Stuff to change: Some sanding was required to get the rattlebacks to function correctly. Next time I would print at a finer resolution and also try to print the models on their long edges, in the hopes that the tops would be smoother. These do reverse direction but do not spin very much after reversing, and I think further sanding or finer/smoother resolution would improve the action.

Sunday, April 6, 2014

Day 223 - CGR 3-Doodler squiggle tower

Today we finally broke out the 3-Doodler 3D-printing "pen". Calvin loves making tall towers of squiggles. This one broke the record!


Technical notes, Yaya-comparison flavor: We also have the Yaya 3D Pen, which is a nearly identical knockoff to the 3-Doodler except that it seems to be (a) lower quality and (b) more expensive. On the other hand it shipped quickly and works pretty much the same way with similar results. One big difference is that with the Yaya you have to withdraw the filament by running the motor backwards, and you can't let the end of the filament disappear into the pen. In contrast, the 3-Doodler lets you just keep running the filament through the pen even when it runs out, which means that you can feed in new filament right behind the old. Calvin loves this because you can do a color-change with a funky transitional color along the way. The 3-Doodler also seems a little safer and has a cover for the nozzle that keeps young fingers from accidentally touching the hot nozzle. You can also switch between ABS and PLA with the 3-Doodler and the packaging and filament collection is much nicer.

Saturday, April 5, 2014

Day 222 - Cube screw-puzzle

Today we printed the four-piece cube puzzle from GeorgeHart's Five Screw-Puzzles model on Thingiverse. This one is very easy in comparison to the tricky tetrahedron puzzle from that set of models, which we printed on Day 104, but it is a good warmup to the trickier puzzle since it works basically the same way. And just as importantly, it makes a really beautiful two-color model.



Settings: We used a MakerBot Replicator 2 on .2mm/standard with a raft but no supports, on blue tape over a glass build plate. The model printed very nicely without supports and required only minimal cleanup and edge-smoothing with a knife. We printed two of them in different colors in order to make 2-color models. It looks particularly good with one translucent and one opaque filament color.

Stuff to change: The resulting model is very loose so next time I would try printing on .3mm/low to see if things tighten up a bit. Also the very tips of the square ends of the pieces got sliced very thin and came off during cleanup. Nobody looking at the model would notice this unless you pointed it out to them, but it contributes to the overall looseness. The thin area could be fixed by extending the square ends of the pieces just a little bit further.

Friday, April 4, 2014

Day 221 - Friday Fail: CubeX Trio edition

Let's start on a positive note. This week the CubeX Trio in the JMU 3-SPACE classroom printed something! Specifically, the giant hand model that comes as a demo with the CubeX software:


Settings: CubeX Trio in draft/fastest mode, in one color PLA.

This success is really the result of failure, but not in the positive keep-trying-and-you'll-learn-and-succeed-eventually way that I usually talk about. No. This time our success is the result of failing repeatedly and eventually giving up. This print represents the day that we gave up on trying to make the CubeX Trio print in multiple colors and decided to use it as a large-scale one-color printer.

Back in October we did a head-to-head test between the CubeX Trio and the Afinia H-Series, which you can read about on the JMU MakerLab blog. That one-color model was the first print we had made on the CubeX Trio, and also the last successful print we did on that printer until today's giant hand, over six months later. The problem was printing with multiple colors. Here is our first multicolor print; it was supposed to be a set of pieces for two-color puzzle with red raft and support material.


If you're wondering how that big blue blob fits into the puzzle, the answer is that it doesn't; it's what got built up around the nozzle in our print catastrophe:


What went wrong with this and all of our other multi-color prints was that there was a problem with the filament-swap step. Specifically, when one nozzle is done printing a layer and it is time to switch to a nozzle with a second color, the nozzles go to the back of the machine and generate some waste material. This waste material is then supposed to be knocked off and into a collection bin by a "wiping stick". In the video below you can see that our wiping stick can't manage to reach the red blob and knock it off:


If anyone writes to me now to say that we just need to recalibrate the jet offset or the height of the wiping stick, I think I will scream. My infinitely patient student Zev and I spent most of fall semester doing just that, with lots of help from customer support and various printed and emailed sets of instructions. We've had things aligned in every way that you can imagine and the video above is just one of many examples. The blobs that get stuck to the wiping blade eventually end up getting stuck to the nozzle later and ruining the print. In the end, CubeX customer support actually told us that they were out of suggestions, and agreed to swap out our machine for another identical machine. Although the second machine was better, we still couldn't get multi-color prints to work. Here's our best try at printing three small cubes in three colors at the same time; note that we didn't make it past the first couple of layers:


So I guess part of failing over and over again is just knowing when to give up. This week we decided to give up and print a one-color demo model just to prove that the machine can do something, and that's today's giant hand model. Although the wiping stick got the last laugh even here; the arrow in the picture below shows the wiping stick catching on the model after slipping down from its aligned location. We had to stop the print and unscrew the wiping stick to finish the hand.


So what's next for the CubeX Trio, now our one-color large-scale printer? Stay tuned for a huge model of Henry Segerman's Dragon Curve from yesterday, as well as some of our Catalan Wireframe Polyhedra from Day 212

Thursday, April 3, 2014

Day 220 - Dragon Curve

Today we were very excited to print Henry Segerman's stunning Developing Dragon Curve model. Henry sent us the file for the model so we could print a small test run of it before attempting to print a supersize model on our large printer (more on that tomorrow). It's a Level 11 and it looks amazing! I brought this print to the NYC Inside 3D Printing Conference to give to Joe Scott from Afnia to thank him for inviting me to speak on a panel at that conference. Thank you, Joe!


Link to Shapeways: Henry has made this fantastic model available on Shapeways at http://www.shapeways.com/model/600153/developing-dragon-curve.html.

Settings: .3mm default fast on an Afinia H-Series, with raft and support.

Technical notes, support flavor: The supports were minimal because of the shape of the model; even the "windows" had very little support, and that support was needed only for the tops of the windows and fell outside of the holes because of how the model curves. Here is a picture of the model with supports still intact, hot off the press:


Technical notes, clean-up flavor: The matte color of the Afinia's ABS plastic filament is fantastic, but small white marks get left in the locations from which rafts and supports were removed. To get rid of these white marks just apply heat; we do this with a Nicole Heat Embossing Gun and it works in just a couple of seconds.

Technical notes, math flavor: Below are two in-depth sources for more information on the mathematics behind the shape and construction of this beautiful model.
  • Numberphile's excellent Dragon Curve video, in which he explains how the Dragon Curve can be built up by folding a long strip of paper. Cool bonus fact I learned from this video: the Dragon Curve was featured in the chapter headings of Michael Crichton's Jurassic Park book.
  • The Irving/Segerman paper Developing Fractal Curves, which explains both the Dragon Curve itself and their method for building a continuous rounded model of its iterations using Bezier curves and a healthy dose of serious mathematics.

Wednesday, April 2, 2014

Day 219 - Chmutov-Schwartz minimal surface

Today we printed elgolem's Chmutov-Schwarz minimal surface model on Thingiverse, in honor of George Hart's wonderful bouncy circle sculpture from G4G11.


Thingiverse link: http://www.thingiverse.com/make:72978

Settings: To print this object we had to convert from obj to stl (used MeshLab); it was huge so we then reduced the scale twice by 50%.  Printed on a MakerBot Replicator 2 with .3mm/low layer height, with raft but no support. The raft was needed; without it the circles on the bottom layer wouldn't adhere to the platform (blue tape on glass).

Stuff to change next time: The bottom of the model is very rough and either needs finer resolution or support for future prints. The rest of the model did very well without supports.

Tuesday, April 1, 2014

Day 218 - Poly/giraffe bracelet

Today we designed a bracelet by using TopMod to extract a ring of irregular pentagons from the center of a Pentagonal Hexacontahedron wireframe (our "giraffe polyhedron" from Day 194). We made small and large versions. The large should fit over most hands and form a bangle bracelet. The small is for those of you with more lady-like hands. For those with larger hands like me, you can cut off a couple of rungs of the small version to make a C-shaped bracelet that is easy to put on and take off, and fits more snugly, as in this picture:


Thingiverse link: http://www.thingiverse.com/thing:288182

Settings: MakerWare custom profile to minimize support (same as our previous knots and polyhedra).

Monday, March 31, 2014

Day 217 - Customizable Tree

Today we printed the Customizable Tree from Thingiverse. A lot of my students at JMU 3-SPACE try to print trees from Marissa's Tinkercad community shape script or other sources, but those models often don't print correctly, and usually end up causing a lot of heartbreak. Thingiverse's new customizable model generates a printable tree every single time! Here's the one that I generated:


Thingiverse link: http://www.thingiverse.com/make:71874

Settings: Printed on a Replicator 2 with .3mm/low resolution, and it looks great.

Technical notes, humble flavor: I was going to post here about the new 3D Vector OpenSCAD Library and how it is used in this model. Since the Customizable Tree is available in the Thingiverse Customizer, you can look at its OpenSCAD code; I hoped to pick it apart and tell you all how it works. Being a math prof I figured vectors are right up my alley and that I would have a lot to say about this. However it turns out that I am not yet smart enough to figure out what is going on in the Customizable Tree code. It looks like I have a lot of OpenSCAD-studying to do this summer. Kudos to the real makers out there who actually know what they are doing!

Sunday, March 30, 2014

Day 216 - Tiling space with a weird squiggle

I've been having fun watching the math that Mike Lawler (@mikeandallie on Twitter) and his kids discuss on video at their blog mikesmathpage, and thinking about how to get my own 8-year-old son interested in watching those videos. Their post from yesterday, Penrose tiles and some simple 3D variations, has three great videos that are very visual and so I started with those. In these videos Mike and his kids examine various tilings of 2-dimensional space and various tessellations of 3D-space, using the following models:
Much thanks to Mike and his kids for making their mathematical journey available for others to learn from, and also for using our models as part of their explorations!

In the second video, Mike and his kids show that two very odd shapes can be used to fill 3-space because pairs of them can combine to make a cube, which of course fills space. In their third video they use 3D-printed models and ZomeTools to show that Rhombic Dodecahedra also fill space. The following model combines these two ideas, using four copies of an even stranger object to construct a Rhombic Dodeahedron:
And that's the weird squiggle that we'll be filling space with today:



Settings: Printed on a Replicator 2 with raft but no supports, on a glass platform with blue painter's tape, at 80% scale, with two pieces of each color. On .3mm/low the pieces took about 12 minutes each to print and made a model was very tight and difficult to assemble, and nearly impossible to take apart. On .2mm/low the pieces took about 16 minutes each to print and have the same problem. Hopefully the clearance will loosen up with repeated use, but if not then I will try to figure out the OpenSCAD code that made this model so that I can increase the clearance.

Technical notes, OpenSCAD flavor: VeryWetPaint made their code available and I'm going to attempt to annotate it to make clear how it works. To understand this code you'll need to learn about Minkowski sums and .dxf extrusion in OpenSCAD.  Here are some things I don't understand yet about this code: (1) why does it seem like the two helical pieces that are removed in the "difference" operation are so different, and (2) how was the .dxf file made and what is the equation for whatever that helix is? I'll update later if I figure it out; please comment below if you know!

// mathgrrl annotation of rhombic puzzle piece code
// code by VeryWetPaint on Thingiverse
// http://www.thingiverse.com/thing:12489

/////////////////////////////////////////////////////////
// parameters ///////////////////////////////////////////

sz=30;
sa=sz*1.5;
tw = 240;

/////////////////////////////////////////////////////////
// module for making a rhombic dodecahedron /////////////

// here VeryWetPaint has the elegant idea to contruct the 
// Rhombic Dodecahedron by intersecting six rectangular solids 

module rhomb()
{
minkowski()
{
  // take six rectangular solids and intersect them
intersection()
  {
rotate([45,0,0]) cube(size=[sa,sz,sz],center=true );
rotate([-45,0,0]) cube(size=[sa,sz,sz],center=true );

rotate([0,45,0]) cube(size=[sz,sa,sz],center=true );
rotate([0,-45,0]) cube(size=[sz,sa,sz],center=true );

rotate([0,0,45]) cube(size=[sz,sz,sa],center=true );
rotate([0,0,-45]) cube(size=[sz,sz,sa],center=true );
   }

// this sphere rounds all of the edges with Minkowski sum
  sphere(r=2,$fn=16);
}
}

/////////////////////////////////////////////////////////
// render of twisty piece ///////////////////////////////

// here VeryWetPaint takes away two corkscrew pieces from the 
// Rhombic Dodecahedron, leaving one corkscrew piece behind

difference()
{
// start with the Rhombic Dodecahedron
rotate([0,0,45]) rhomb();

// take away one corkscrew piece
linear_extrude( 
file="spiral.dxf", 
height=36*1.7320508075688772935274463415059, 
center=true, 
origin=[28.782,28.43], 
twist=tw, 
slices=64 );

// take away a rotation of that same corkscrew piece
 rotate([0,0,120/4]) 
linear_extrude( 
file="spiral.dxf", 
height=36*1.7320508075688772935274463415059, 
center=true, 
origin=[28.782,28.43], 
twist=tw, 
slices=64 );
}

UPDATE: Scott Elliott (VeryWetPaint) has uploaded a new .dxf file and OpenSCAD code on Thingiverse with some helpful descriptions and bonus OpenSCAD code in the comments below. Thank you, VeryWetPaint!

Saturday, March 29, 2014

Day 215 - Great Dodecahedron from Generated Polyhedra Code

Today's print is a Great Dodecahedron designed by kitwallace, author of The Wallace Line blog and master constructor and compiler of polyhedra. He'll be guest-posting later to talk about his OpenSCAD polyhedron models, but for today we have a test print:


The model is really nicely designed and has a uniform thickness all around, as you can see in the action photo below.


Thingiverse link: http://www.thingiverse.com/make:71361

Settings: MakerWare .3mm/low with a raft. The raft is needed because although the model was oriented on the platform so that it rested on a triangular face, the angles at the edges made it so that only a thin triangle of material was in contact with the build platform. The raft helps everything stay put with a larger contact surface.

Friday, March 28, 2014

Day 214 - Friday Fail, raft edition

Here's my favorite fail from this week: a botched print of three Fidget Cubes. It's partially my favorite because I happened to have been sitting right next to the machine when it happened so I could stop it right away before the dreaded "giant blob built up around nozzle" problem kicked in.


It's also my favorite because it helped me to figure something out. I recently switched from the MakerBot acrylic build plate that ships with the Replicator 2 to a glass build plate that I bought on Amazon. When using the acrylic plate, this is the order I would see for platform adhesion (loosest adhesion on the left, most stick-to-it-iveness on the right):

Acrylic-with-tape   <   Acrylic-with-raft   <   Acrylic

Now that I'm using a glass platform, the tape actually makes things adhere better to the platform, not worse, since glass alone is so bad for adhesion. Since I had formerly used rafts to make things stick less to my acrylic platform, it didn't occur to me today to try to use them to make things stick more, even though it is obvious that a raft should make things stick better to tape no matter what the tape is on! With glass platforms, we have this adhesion order (again, loosest on the left):

Glass   <<   Glass-with-tape   <   Glass-with-tape-and-raft

Anyway, long story short, now I'm using Glass-with-tape-and-raft for my prints, and I'm getting a lot fewer "blob" errors. And even better, figuring out this fail helped me to figure out another.

On Day 208 I started printing out a great many 26mm Level 3 Menger cubes. (Side note to @standupmaths - I actually put the package in the mail today, can you believe that? Two months earlier than usual.) Lots of the prints were turning out like Day 207's free-floating half-Menger-attached-to-blob, and no amount of re-leveling the build platform, installing fresh blue tape, or "just trying one more time to see if the problem would magically stop" was fixing the problem. Until we tried printing with a raft - not because the raft made it stick better, but because it turned out that for this model the raft was really really small and didn't cover the base; see the left object in the picture below (shown upside-down so you can see the tiny raft).


Mystery solved! The raft thinks that the first layer of the model is really small. Which means that a tiny dot in the center of the model must be too low: at least for very small sizes like this 26mm cube, a little piece of the bottom center corner of owens' Customizable Menger Sponge sticks down too far and needs to be sliced off.

We went into OpenSCAD and sliced off the very bottom of the model (here "owens_code" is the part of the code where owens' Menger-with-stand object is generated, and we are taking away from that object a cube that sits right under the xy-plane):

difference(){
owens_code();
translate([0,0,-20]) cube(40,center=true);
}

As you can see from the model on the right in the picture above, this change worked; the raft now covers the entire stand and we got a very sturdy print. Thank you once again, failure, for pointing us in the right direction!

Thursday, March 27, 2014

Day 213 - Han Solo Lithopane

Today I rest, and print atartanian's Han Solo Lithopane design from Thingiverse, based on MakerBot's Customizable Lithopane design from last year. Thank you for making this possible, internet!


Now this is pretty cool, but I nearly fell over when I saw how amazing this thing looks like when light shines through it. Let me stress: the picture below is of the same object as the picture above!


Thingiverse link: http://www.thingiverse.com/make:71359

Settings: Printed on a Replicator 2 with a glass build plate and blue tape. As recommended for lithopane designs, this was printed at .2mm/standard layer height with light-colored filament. We used MakerBot's excellent "Warm Gray,"our favorite filament for Serious Prints. (And which we think should be called "Bone" instead, in case anyone is listening.) Our new glass building plate did a great job; it is clearly much, much better than the old acrylic plate for printing things that are large, thin, and flat.

Stuff to change later: If I printed this again I'd use a linear fill instead of the standard hex fill; as you can see in the second photo, Han looks like he is sporting a hex-quilted vest. :)

Wednesday, March 26, 2014

Day 212 - Stylized Catalan Wireframes

Our Catalan Wireframe Polyhedra series is finally complete! Here is the whole happy family of thirteen:


Settings: MakerWare .3mm/low with support-reducing custom slicing profile, on a Replicator 2. We printed each one in a different color with scraps from home and work so that they would be easy to identify. Each model was scaled by a constant that measured the openness of its design, so that together the models would look like a matching set. The wireframe designs were made using Mathematica, MeshLab, and TopMod. Everything in this paragraph is described in detail below.

Thingiverse link: http://www.thingiverse.com/thing:282868

Technical notes, nomenclature flavor: Which polyhedron is which? Every face of a Catalan solid is the same non-regular polygon, and the prefix of its name describes the kind of face that it has.
  • Triakis = faces are isosceles triangles arranged in 3-sided pyramids
  • Tetrakis = faces are isosceles triangles arranged in 4-sided pyramids
  • Pentakis = faces are isosceles triangles arranged in 5-sided pyramids
  • Rhombic = faces are rhombi/rhombuses (grammar police line up and fight!)
  • Didsyakis = faces are scalene triangles
  • Deltoidal = faces are kites
  • Pentagonal = faces are irregular pentagons

Technical notes, differentiation and scaling flavors: The following is a key to the Catalan solids pictured above, together with the respective scaling factors as calculated using the algorithm we explained on Day 195:
  • BLUE = Triakis Tetrahedron, scale 1.99498 (Day 211)
  • BLACK = Triakis Octahedron, scale 2.01059 (Day 202)
  • TRANS. ORANGE = Triakis Icosahedron, scale 2.06374 (Day 199)
  • NEON ORANGE = Tetrakis Hexahedron, scale 1.83142 (Day 211)
  • NEON GREEN = Pentakis Dodecahedron, scale 1.83261 (Day 204)
  • GREEN = Rhombic Dodecahedron, scale 1.45648 (Day 210)
  • WARM GRAY, scale 1.49535 = Rhombic Triacontahedron (Day 203)
  • TRANS. YELLOW = Disdyakis Dodecahedron, scale 1.72338 (Day 195)
  • TRANS. CLEAR = Disdyakis Triacontahedron, scale 1.6772 (Day 205)
  • RED = Deltoidal Icositetrahedron, scale 1.43823 (Day 198)
  • TRANS. PURPLE = Deltoidal Hexecontahedron, scale 1.28527 (Day 196)
  • WHITE = Pentagonal Icositetrahedron, scale 1.13082 (Day 197)
  • TRANS. BLUE = Pentagonal Hexecontahedron, scale 1.00 (Day 194)

Technical notes, support flavor: Starting from the "Standard PLA" MakerWare .2mm profile with raft and supports, we changed the settings listed below. This is the same knot/wireframe support-reducing profile that we have used many times before, posted here just so you don't have to go find it:
  • "roofThickness": 0.5, 
  • "floorThickness": 0.5,  
  • "sparseInfillPattern": "linear",  
  • "infillDensity": 0.2,   
  • "minSpurLength": 0.4,  
  • "doSupport": true,
  • "doSupportUnderBridges": true,
  • "supportDensity": 0.1,   
  • "supportExtraDistance": 0.8,  
  • "supportModelSpacing": 0.5, 

Technical notes, modeling flavor: The following is the workflow used to obtain these models. Most of this was described in Day 194 but we repeat it here for completeness and to insert the scaling step that we added in Day 195. We'll walk through with the Pentakis Dodecahedron as our example.
  1. Use Mathematica to create the polyhedron and export to STL, and then calculate the scaling factor for the model:

    PolyhedronData["PentakisDodecahedron"]

    Export["PentakisDodecahedron.stl", %]

    N[
 PolyhedronData["PentakisDodecahedron", "EdgeLengths"]]
      
 Out = {1., 1.12732}

    length = (2*1 + 1.12732)/3
    
   Out = 1.04244

    
 edges = 
 PolyhedronData["PentakisDodecahedron", "EdgeCount"]
       Out = 90   

    surface = N[PolyhedronData["PentakisDodecahedron", "SurfaceArea"]]

       Out = 27.9352

    scalefactor = Sqrt[(length*edges/surface)]
       Out = 1.83261


  2. Use MeshLab to resize and convert to OBJ format:

    Import STL

    Filters --> Normals, Curvature, and Orientation/Scale
    to set the scaling factor

    Export as OBJ


  3. Use TopMod to remove edges or vertices that don't belong in the wireframe, and then create the frame and remesh:

    Import OBJ

    Wireframe 0.250

    Remeshing/4-Conversion/Linear Vertex Insertion

    Remeshing/4-Conversion/Doo Sabin

    Export as STL


  4. Use MakerWare to size and orient the model:

    Import STL

    Allow MakerWare to rescale or do manually with 2450%

    Scale to 50%

    Orient model to reduce support

    Slice and print with Custom Slicing Profile

UPDATE: This set of models was "Featured" on Thingiverse on April 22, 2014, hooray!

Tuesday, March 25, 2014

Day 211 - ...And the Rest

Or the Professor and Mary Ann, as they prefer to be called. Our last two Catalan solids are the Triakis Tetrahedron (dual of the Truncated Tetrahedron and Kleetope of the tetrahedron) and the Tetrakis Hexahedron (dual of the Truncated Octahedron and Kleetope of the cube/hexahedron). And now that I have them here side-by-side, I finally get what "triakis" and "tetrakis" mean: the former means that triangular pyramids were added to obtain the object, and the latter means that square pyramids were used.


Thingiverse link: http://www.thingiverse.com/thing:282534

Settings: Same as the last week of Catalan prints. Stay tuned tomorrow for a round-up of the slicing, sizing, and mesh choices that built this set of thirteen wireframe polyhedra.

Monday, March 24, 2014

Day 210 - Rhombic Dodecahedron

We're almost at the end of the Catalan series! Today we printed our eleventh, the Rhombic Dodecahedron, dual of the Cuboctahedron (which we also constructed with printed snap-tiles on Day 87).


Thingiverse link: http://www.thingiverse.com/thing:282499

Settings: MakerWare .3mm/low with custom reduced-support slicing profile, on a Replicator 2.

Technical notes, tessellation flavor: The Rhombic Dodecahedron has a very interesting property: it fills space. What I mean by that is that you can stack them up to pack together perfectly, with no open spaces between.  This is a pretty rare property: the only Platonic solid that fills space is the cube; the only Archimedean solid that fills space is the Truncated Octahedron; and the only Catalan solid that fills space is the Rhombic Dodecahedron.

For more information see "Simplicity is not Simple: Tesselations and Modular Architecture", the cover article for Math Horizons about Gregg Fleishman's space-filling housing units that I wrote with Eugenie Hunsicker of Loughborough University in 2002.  Twelve years later I can now finally stack up a handful of Rhombic Dodecahedra and see for myself!

Sunday, March 23, 2014

Day 209 - Afinia Menger

Most of our prints for this blog are made on a MakerBot Replicator 2, since that's what we usually have at the house. But the other day one of the Afinia H-Series printers from the JMU 3-SPACE Classroom made a guest visit, on its way to the Expanding Your Horizons Conference, where Rebecca Field gave a wonderful 3D-printing demonstration and math talk to a large group of middle-school girls. While the Afinia was here, Rebecca printed a demo Menger cube using owens' Customizable Menger Sponge model from Thingiverse. It worked wonderfully!


Settings: Afinia 3D .3mm default fast, with a raft and with custom stand included in the model but no supports.

Thingiverse link: http://www.thingiverse.com/make:71022

Saturday, March 22, 2014

Day 208 - 26mm Level 3's and the Sketch A Menger Cross-Section Competition™

I love to root for the underdog: David vs Goliath, Buffy vs the entire Hellmouth, the Baudelaire twins against Count Olaf and his evil theatre troupe. Today the role of the underdog will be played by the affordable consumer-level MakerBot Replicator 2 ($2,200), going head-to-head with the wickedly expensive Dimension Elite ($24,000 + $3K/year service contract) at the JMU Engineering Department. Of course, since Stratysys acquired MakerBot last year, this is a friendly fight indeed. :)

Battle time! We used owens' Customizable Menger Sponge design on Thingiverse to print a 26mm Level 3 Menger cube, pictured on the left below. John Wild in Engineering was kind enough to use the Dimension Elite to print a 26mm Level 3 Menger cube for us last summer, pictured on the right. The Dimension Elite prints with a dissolvable support material, so they didn't have much trouble removing the supports from this tiny model. Our model on the left didn't need any supports at all since it was printed on its corner(!), so the holes are actually clearer on our Replicator 2 model. It looks great!



Settings: A 26-mm Level 3 model prints up in just under 90 minutes with no raft or support with MakerWare .2mm/standard on a MakerBot Replicator 2. You can even get a decent print using the .3mm/low resolution! The model prints on its corner, supported by a very clever custom stand designed by owens on Thingiverse.

Thingiverse link: http://www.thingiverse.com/make:71021

We love these so much, we are printing them whenever we have the chance. If we make enough of them we could stick them together build a Level 4!


Three of these six small Menger cubes will be prizes in the the Sketch A Menger Cross-Section Competition™ that was held at this week's G4G11 Conference in Atlanta over Twitter, by Matt Parker from the mathS department at Queen Mary, University of London. (Be sure to also check out Matt Parker's online shop mathsgear.co.uk and website standupmaths.com.) 

Matt is @standupmaths on Twitter, and he asked his army of followers to try their luck at sketching Menger cube slices. There were an amazing number of very good submissions, with things I never could have drawn by hand without looking at the actual model! We chose three winners and I've added a runner-up:

Jose Barrera (@JBarreraGT) took first place with three really amazing sketches:




Dawn R (@Boneist on Twitter) took 2nd place with this unique choice of slice:


Sadie Robertson (@Saddle098 on Twitter) took some time off from working out circuits to win Honorable Mention:


And Alex Hunsley (@quaplek on Twitter) had a late entry with some of the most beautiful paper I have ever seen:


Thank you Matt Parker and everyone who submitted entries to the slice-drawing competition! Perhaps we can have more competitions in the future...

Thursday, March 20, 2014

Day 206 - Menger coverups

At this year's Gathering for Gardner Conference (G4G11) I gave a short talk about 3D printing sliced Menger sponges. So that people could look at the sliced models and guess what the sliced face looks like, I made some white printed coverups to hide the sliced faces.




Thingiverse link: slice-covers added to the model set at http://www.thingiverse.com/thing:250557

Settings: MakerWare .3mm/low. The cover shapes can be held onto the Menger slices with poster tack, although this does sometimes leave a small amount of blue residue on the model afterwards.

Congratulations to Glen, Tanya, and Daniel for winning the Menger-slice-drawing contest at the conference; each got a 43mm Level 3 Menger sponge (see Day 161) as a prize!

Wednesday, March 19, 2014

Day 205 - Disdyakis Triacontahedron

Today is our largest Catalan print so far, with a diameter of over 120 millimeters - about the size of a very large grapefruit. One cool thing about this model is if you look only at the large 10-degree vertices you see the points of an icosahedron, while if you look at the pentagons surrounding those vertices you see the faces of a dodecahedron. In addition, you can see the rhombuses (rhombi?) of its Kleetope, the Rhombic Triacontahedron, and find 4-, 6-, and 10-degree vertices corresponding the the 4-, 6-, and 10-sided faces of its dual, the Truncated Icosidodecahedron.


Thingiverse link: http://www.thingiverse.com/thing:281174

Settings: MakerWare custom profile described in Day 194, on a Replicator 2, with sizing using the method from Day 195.

Technical notes, support flavor: Near the beginning of this series of Catalan solids, I worried that I'd be spending too much time on one type of model, and that things would get boring. But kind of the opposite has happened, I think: because we are printing the same sorts of things every day, we can take time in these posts to describe more of the math, design, and technical things that go into the prints. For example, we've barely talked about support - except of course to mention that we're using the support profile we made for knots and Catalan solids, described on Day 194. But how much support is that? How much cleanup is required for these models? Because this model is very large and has particularly small, thin, triangular openings, it is a good worst-case scenario to explore. So we took some pictures along the way this time...

As you can see in the picture below, we chose to print the model on one of its large, high-degree vertices. We previewed the slicing in this orientation and in the "flat on one face" orientation, and this one took less support, plastic, and time. I think it is because the edges coming up from the large vertex are at a significant angle, while the edges that extend around a triangle face are much more horizontal and therefore would need more support. In the picture you can see that support towers are being built to hold up the top edges of the model, but that the lower edges themselves do not need much support.


In the next picture we see the finished model, with thin support towers up to the top:


From the front we see the thin curtains of support towers that are hiding under the edges:


Removing the support is not that difficult, because the support is very thin and also not that securely attached to the model. It took me just under five minutes to remove the support from this large model, by snipping to break the support and then pulling it out from the holes. The cleaned-up model weighed in at 45 grams, and the pile of support weighed only 37 grams.


Tuesday, March 18, 2014

Day 204 - Pentakis Dodecahedron

Yes, we seem to have fallen behind again. We can talk more about that on some "Friday." For now we'll catch up with the rest of our Catalan prints and some additional Menger prints before getting on to new designs.

Before we start, I want to give a shout-out to three people on Thingiverse that have been doing excellent work with polyhedra:
Today's Catalan solid is the Pentakis Dodecahedron, dual of the Truncated Icosahedron (aka "soccer ball,' aka "football," depending on where you live).


Thingiverse link: http://www.thingiverse.com/thing:281166

Settings: MakerWare custom profile described in Day 194, on a Replicator 2, with sizing using the method from Day 195.

Monday, March 17, 2014

Day 203 - Rhombic Triacontahedron

This Catalan solid is the Rhombic Triacontahedron, the dual of the Icosidodecahedron (which we've already printed twice before as a snap-together model, in Day 89 and Day 117).


Thingiverse link: http://www.thingiverse.com/thing:274427

Settings: .3mm/low on an Afinia H-Series, with the support density reduced to 2 layers in order to make the supports easier to remove.

Technical notes, build platform flavor: This was my first print using Afinia's Borosilicate Glass build plate and BuildTak Platform Surface. Both worked wonderfully, with the glass seeming to get much hotter all the way to the edges than the usual Afinia perf board, and the BuildTak providing the necessary adhesion (although it itself is not sticky, just rougher than the glass). I do need to find some larger binder clips, however, because mine are a bit too small to hold this new setup in place. I'll do a "print to the edge" test on the glass+BuildTak combination later this spring.

Technical notes, filament flavor: This model looks snowy white because of the great matte colors you can get with ABS, especially the Afinia Premium. Most of the PLA filament I've used is a bit too shiny for my taste, with the exception of MakerBot's wonderful translucent PLA filament colors. If you're looking for a matte PLA then the best I can recommend is MakerBot's "Warm Gray", although they are currently out of stock for the Replicator 2. However, you can order it for the 5th-gen Replicators and it will be the same filament, just on a thinner and taller spool that looks somewhat like a film reel. You can't use the 5th-gen spools on the Replicator 2 but you can rewind the filament onto an old-style MakerBot spool or use a separate filament stand.

UPDATE: The Rhombic Triacontahedron wireframe is the shape made by Roger vonOech's StarBall puzzle, which I just bought from Robert Fathauer's lovely shop at G4G11.

Sunday, March 16, 2014

Day 202 - Triakis Octahedron

New fact of the day: If you add a pyramid to each face of an octahedron, then you are taking its "Kleetope." A cool new word for me, leading to the next Catalan solid in our list: the Triakis Octahedron.


Thingiverse link: http://www.thingiverse.com/thing:274367

Settings: MakerWare custom profile described in Day 194, on a Replicator 2. Sizing was determined using the method from Day 195; at the end of the Catalan series we'll do a recap, including the sizing parameters for each polyhedron and how they were obtained.

Technical notes, design flavor: The Catalan wireframes I've been printing are a bit stylized, with vertices that become larger according to their degree. This is because of the remeshing that I am choosing in TopMod, specifically the "Doo Sabin" remeshing. I went with this because I like that I can easily differentiate between different types of vertices; for example, in today's model the vertices that belong to the underlying octahedron (before the "kleetoping") are larger and stand out, while the vertices that form the topes of the added pyramids are smaller. In addition the extra bit around each corner helps make a very stable model that can be dropped on the floor, thrown, and otherwise abused without breaking.

Technical notes, Kleetope flavor: We printed a Kleetope earlier, on Day 199; the Triakis Icosahedron was the Kleetope of the icosahedron. In fact, each of the Platonic solids gives rise to a Kleetope that is a Catlan solid with isosceles-triangular faces:
  • the Triakis Tetrahedron is the Kleetope of the tetrahedron;
  • the Triakis Octahedron is the Kleetope of the octahedron;
  • the Tetrakis Hexahedron is the Kleetope of the cube (a.k.a. the hexahedron);
  • the Pentakis Dodecahedron is the Kleetope of the dodecahedron; and
  • the Triakis Icosahedron is the Kleetope of the icosahedron.
Technical notes, capitalization flavor: I have decided that Catalan solids are cool and deserve to be capitalized, but I can't bring myself to capitalize my old friends the Platonic solids. Somehow they look silly all dressed up like that. Sorry, capitalization police.