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For the course Technologies for Concept Design (TfCD) at the TU Delft we demonstrated an emerging technology through a prototype.

The starting point of our Instructable was the idea of printing hard and soft material in one print with an cheap 3D printer. It is possible with a very expensive printer (Connex 3), but what if this was possible with an Ultimaker? Building upon a project on Instructables.com (https://www.instructables.com/id/Super-flexible-duble-curvature-surface-laser-cut-p/) which was about creating double curved wood with the help of patterns.

Step 1: From Pattern to Print

As a first step towards an application with this double curvature implemented, we will try to identify the what settings, dimensions etc. works best.

Making the retrieved pattern usable for 3D printing was done with the help of Illustrator and Solidworks. In general, a wall thickness must be created to use the sketch in Solidworks and a printable object must be created in SolidWorks. The different steps in Illustrator, Solidworks and 3D printer (Ultimaker) will be shortly explained here below.

Steps in Illustrator:


- Select path (the pattern)

- Offset path (Object → Path)

- Minus Black (Effects → Pathfinder)

- Create a fitting stroke

- Create rounded corners (Effects → Stylize)

- Expand appearance (Object)

- Remove stroke Export to a dwg file (keep the settings in mind, we used inch : 1 on 1) (File → Export)

Steps in SolidWorks:

- Open file (File → Open)

Select: All Files (*.*)

Select the DWG-file Click:

Open Select: Import to a new file as 2D sketch

Click: Next (Check preview)

Click: Finish

- Boss extrude sketch Select sketch (Model)

Extrude sketch (Features → Extruded Boss/Base)

Type the thickness D1 (Direction 1)

Click: Ok

- Save as STL-file (File → Save As…)

Select: STL (*.stl)

Choose filename

Click: Save

Steps in Cura:


- Expert → Switch to full settings

- Basic → Quality: Layer height: 0.25 mm (max for Ultimaker2)

- Advanced → Quality: Initial layer thickness: 0.0 (same as other layers)

- Load STL-file Save toolpath → click save

<p>Are there any instructables on the other steps towards implementation of a flexible surface in a product?</p>
<p>Amazing work guys.</p><p>I would appreciate if you could send me the .dwg file at javaid_butt@outlook.com</p><p>Again great work :)</p>
<p>Hi Ben and Lukas, thanks for this instructable. I would like to try laser cut it but cant seem to find the .dwg file could you perhaps send it to me please?</p><p> many thanks guys.</p><p>regards marc</p>
<p>What a &quot;Brain you Have&quot;.</p>
<p>Looks great, but wouldn't it be polite to include a link to the project that inspired you?</p>
<p>Very, very cool. Maybe we could combine it with magnetic hinges</p><p>https://www.instructables.com/id/Magnetic-Hinge-With-3D-Printing/</p>
<p>This is really cool. It's the kind of thing that you can't do by hand.</p>

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