Heydar Aliyev Centre Construction Massing + Problem Solving

Due to the large amount of data, computation time on Rhino and Grasshopper has taken a while to ready the model for 3D printing.

As the model needs to be sprayed, printing on the Form 2 (resin printer) was a possible option. However, as all sections need to be 3D printed the cost would have been unreasonable and unnecessary. Due to less overall bed space, waiting times would be longer and components would need to be broken down into smaller pieces. Potentially compromising panelling detail and structural integrity through additional filling, further increasing production time. Making SLS printing a perfect alternative.

Form 2 printer bed

Now that these components have been printed, the only issue with the construction of the model has been lack of ability to print the entire thing in one piece. Meaning that each section of the model must be glued together using epoxy. This process takes time. There have been a few instances where the joints weren't strong enough resulting in me having to remove the glue and re attach them. Whilst this has been successful these joints need filling.

For this, I considered the use of car body filler. However, the colour and texture wouldn't match. In addition to this the flexibility in the unfilled, 2mm thick print would have caused cracking in the car body filler. Having a negative impact on the finished model.

Other solutions such as Polyfilla were under consideration. Unfortunately, whilst matching the print in colour and texture, this doesn't set properly and is prone to marks. Also not improving the durability and strength of the model.

Filler test, Polyfilla (right) PVA + SLS mix (left)

To solve this, I developed my own filler using a mix of PVA glue and SLS powder. This proved to be an appropriate solution as it sets strong and matches in colour and texture.

Whilst producing a durable model this does come with some draw backs as the filler has to be sanded back, which could have potentially resulted in damaging the fine panelling detail. The filler was therefore applied as cautiously as possible, adding back in any panelling joints that became clogged using a needle file. This has proved to be an excellent, uncompromising solution and further developed my problem-solving skills in preparation for industry.