For this project I used Fusion 360 to generatively design a 3D printable holder for my AirPods case.

Supplies

Software: Fusion 360, Bambu Studio. Hardware: Bambu X1 Carbon, PLA.

Step 1: Identify Goal

Given a small volume to print in and the task of supporting somethings weight, I looked to small objects I used everyday. I decided on my AirPods case as it's small but not super light and has a curved geometry which could be interesting to support.

Step 2: Model Base Geometry

I first created the models to run the studies on in Fusion 360. This includes (1) a body to represent the case, (2) three thin curves which will actually make contact with the case, and (3) the base which will rest on a flat surface (in two variations).

Step 3: Run Study

I marked the body representing the case as obstacle geometry, the other bodies as preserve geometry, the base piece(s) as fixed, and the structural load as 0.6 Newtons divided among three supports (the blue arrows are hidden by the obstacle geometry). The study used a safety factor of 2.

Step 4: Some Variations

I got five distinct models from the studies, two from each base variant. I decided that the six leg version had the most interesting design.

Step 5: Bonus: Topology Optimization

I also ran a topology optimization simulation on a mesh from one of the studies. The results weren't especially interesting.

Step 6: Slicing

In Bambu Studio, I set up the model to be printed. To make it as sturdy as possible, I selected the "Strength" preset which uses 25% grid infill and 6 outer wall loops. Some tree supports were also needed for flatter areas. Because the model was so small, the total printing time was only about an hour.

Step 7: Printing

The final result holds the case well and is structurally sound. The one adjustment I would make would be giving more surface area to the curves that touch the case to make it more stable (the case falls out of the holder easily).

Step 8: Another Bonus: Lampshade Stand

You may remember how last week I made a parametric lampshade with Rhino and Grasshopper, but because of build space restrictions I had to prop it up with cardboard pieces to get it tall enough. Well, I also made a generative 3D printable stand to support it!