RAPID PROTOTYPING - LETTERPRESS TYPOGRAPHY

CAD -OBJECT IN SPACE ! ROD BAMFORD 2008

Create your typeface by extruding a rectangular prism

50 l x 36 w x 21 h dimensions mm

Add 2mm letter height on top of the block.

Create your letter as a closed line 2d.

You can do this by drawing directly in the 3D Modelling software or by

importing an Illustrator drawing file ( the Illustrator file must be and

exported as a version 8 Ai file for import into Bonzai3D of FormZ).

In 3d modelling, 2d shapes are referred to as ʻwiresʼ. When the wire

is enclosed and and filled, it is a ʻsurfaceʼ. Wires and surfaces cannot

be printed, as they provide no three dimensional coordinate

description.We need to transform the surface into ʻsolidʼ geometry.

Once you are happy with the letter form, extrude it to 4mm high. and

check that it is a geometric solid by invoking the ʻpick tool ʼ and

checking the ʻinfoʼ tab in the tool options dialogue.

Position the letterform on the block, then adjust so that it is embedded

2mm into the top of the block protrudes 2mm above the block.

Use a boolean union to join the two shapes. Check to ensure the

geometry is solid.

On completion, export the object as an .stl file. Orientate the typeface

block so that it rests on its edge. This way you will get better

resolution on the 3d printed letter face.

T

YPOGRAPHY FOR LETTERPRESS

RAPID PROTOTYPING FOR LETTERPRESS

CAD -OBJECT IN SPACE ! ROD BAMFORD 2008

Once your typeface model is complete and you have checked

itʼs dimensions are accurate, you will need to prepare it as

an .stl file printing on the Dimensions SST 3D printer.

We need to check both the geometrical integrity of the model

and itʼs resolution. The modelled should be a single object and

have solid, well formed geometry. The minimum practical

dimensional resolution capable of being printed on the

Dimensions SST is 0.5mm.

Once the model is complete, an .stl file is prepared and

exported to the 3D printer software. During this process all the

smooth modelled geometry is converted to facetted

triangulated mesh form.To achieve the best resolution we aim

to create facets which have an edge length close to the

minimum printing resolution. Because .stl files are resolution

independant, we can modify the overall resolution of a mesh

by scaling the model before it is converted to a facetted mesh.

For example, if we want the typeface to be printed at 50mm

height, but our original smooth model produces a course

mesh, we can first enlarge it, the make the mesh conversion,

then re scale the mesh. See the example below.

Cad Object and Space 3177

.stl export

no adjustment

.stl export

additional facet adjustment

Object scaled @200%

.stl export

additional facet adjustment

mesh scaled 50%

RAPID PROTOTYPING FOR LETTERPRESS

DIGITAL WORKSFLOWS FOR DESIGN! ROD BAMFORD 2011

Now export the model as an .stl file.

Before doing so, check the object

resolution slider is set to 100%.

Cad Object and Space 3177

The file you generate will be small and will be

processed quickly , so you may not notice any

prompt.

To check the .stl file, go to

File Menu > Import >

navigate to your .stl file and load it

In the prompts dialogue check Cosntruct 3D solids.

Your file should look something like the image on the

right.

Congratulations, your done. Close the software (donʼt

save)

Then, go to

File Menu > Export > STL

Name the file, press save and the

following dialogue optiions will appear.