seaming 3D parts that are too big to print

[jimgaas]

Since present 3D printers are somewhat limited in their ability to print large pieces, like an entire instrument panel cover, it would be very interesting to me to know whether anyone has seen "seaming" software to create a join that would snap, attach, connect or whatever, two printed pieces of plastic that should normally be one. This would allow the printing of a large piece by splitting up the size to a printable size and place an appropriate seam in the middle, sort of like a tongue and groove. My expectation here is that a person designs a large piece in, say, sketchup, determines how big a piece can be printed and place a seam in an appropriate place that would allow the joining of the two pieces after printing. This would greatly expand the number of plastic parts in a plane that could be printed with the inexpensive printers available now.

[John Nicol]

Hi Jim,

Typically what we do is take the completed part in CAD and then use a 3D printing application to break the larger part into smaller parts and arrange them on the print bed. Then there are various methods used to glue or fuse the parts together into the full-sized part. Here are some techniques:

http://www.stratasys.com/solutions/fini ... and-gluing

You could definitely create the joinery in the CAD model to allow the parts to snap together though.

Here is a great video showing a 3D printed car dashboard printed in 19 parts and then glued and painted:

https://www.youtube.com/watch?time_cont ... IbyYrqtMes

It probably wouldn't take much effort to add snap joints to a CAD model. It then depends on how accurate the printer is to allow all the pieces to line up.

My original thought was smaller instrument panel pieces like bezels and switch covers, but your email and post have me really interested to see how much further we can take it!

John