3D Printed Press Fit

For this assignment, I tried to make a 3D printed Cube which can be fitted together by its different faces without glue. The entire model was build in Rhino, and then sliced using Ultimaker Cura

The entire design was done within Rhino. I used Layers for the first time in this assignment. The different colours for each layer, and disabling certain layers while designing other layers helped in quick design process. With the help of 3 layers, I was able to quickly draw 3 designs for the Top, bottom and the right faces of the cube.

I started with a 6cm X 6cm square, and used the CurveBoolean feature to create a design out the square (Fig 1). And then I used the extrude functionality to lift it by 0.4cm to create a solid face. I duplicated the face to the opposite side (Fig 2).

For the right face(drawn in another layer), I again started with the same sized square and followed the same steps as above to create a slightly different design such that the two faces can be attached to each other. I did a BooleanDifference between the front and the right faces so that the colliding part in the 2 faces are removed (Fig 3).

Same but slightly different pattern was repeated for the top and bottom faces.

Finally the 3 faces of the cube were individually exported and laid out flat on the Cura software for slicing. All the 3 faces are duplicated to create a cube.
With Standard quality and Cube infill, the printing time came out to around 6 hours (still in progress)