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This project is about 3D printing thin and large sheet-like forms that are larger than the printer's build volume. This is done by printing the model in a 'pre-rolled' form, then detaching it from its supports and unrolling after curing. The printer used is the Formlabs Form 2, which is an SLA (stereolithography) printer with a build volume of 145 x 145 x 160 mm.

Check out Part 2 here!

Step 1: Background

The idea of compacting 3D prints to fit inside smaller print volumes isn't uncommon in the SLS (selective laser sintering) print process. A great example is Nervous System's Kinematic Dress, pictured above. It consists of a series of moving triangulated joints that can be printed in a connected and folded configuration.

The SLA print process, on the other hand, relies on a precision laser to cure layers of photopolymer resin. Unlike SLS, SLA involves curing liquid resin, which requires supports and doesn't let you print assemblies with moving parts in a single build.

However, with the right combination of resin type, part orientation and 3D modeling, it is possible to print a compacted model which is larger than the build volume with SLA.

We will be printing with the Formlabs Durable resin, which is more ductile and has higher elongation than general purpose resins. This helps create thin, pliable prints that can be used for anything - from architectural models with complex surfaces to lampshades - all at a scale that is larger than the given build volume!

Awesome idea! This really opens up a lot of possibilities!
<p>I am amazed with the creativity that 3d printers allow. Wow!</p>
<p>Nice flexible 3D printing design.</p>

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Bio: Design at Formlabs | RISD Architecture '16 | Design, technology, fabrication, drawing
More by AashmanG:SLA Textile 3D Print 3D Printing Pre-rolled Sheets 
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