Chunky Prongs

Chunky Prongs

An effective, yet time consuming (hey, this is a hobby, right?) aspect of programming that seems to apply to 3D printing is trial and error. Basically, try something, observe as much as possible on the trial, make adjustments and try again. Slowly but surely, you get something that works.

In this phase now, we are progressing through iterations of trial and error.

This model error has been seen frequently. It means there is something “untrue” with the model. It has an extraneous line or wall inside of it or something similar. Also, circles/curves might be caught in this error, but it is unclear at this time.

Watertight errors everywhere

More errors kept appearing with experiments with the prongs. Eventually, we abandoned round prongs to limit these errors, which seemed to help.

More problems as the shards get more complex

Maybe there is more to learn about creating 3D model pieces that interlock. Perhaps this post can help (Blender focused). Here they describe the “Pin and Cavity” method, similar to what we are doing. They specifically make the prong a cylinder.

Pin and Cavity
Sword tip, viewed in Ultimaker Cura

Cura does not seem to have a problem with a Sketchup cylinder. Hmm.

We thought that circles, curves were problematic. Maybe?

A new idea. Try to make prongs larger and more chunky.

A more complex design that might actually hold together

Resin vs. FDM

Took a side track on Resin vs FDM. Resin can produce finer detail, but has a number of drawbacks, including cost, complexity, etc. My brother’s printer is filament (less detailed).

For a nice rundown, check out:

Resin examples

Orc on guitar
Resin details show through
Frog/Cat?

Filament examples

Doors and The Rock
Dice Castle

This is the last iteration that has made it to the printer, but we have made new changes to it in effort to get the sword to “hold as one”. Basically, we are trying to find prongs that hold.

Looking better!

Here is the latest, the Chunky Prong version.

Chonky Prongs

Part 3 coming soon!!!

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