The first stage was to experiment with low bit files. There were a lot of shapes created, like a sphere, a box and finally an easy-shaped-saddle. All of these shapes were created with Rhinoceros. After this section the 3D reaction models from Avizo were transferred to Rhinoceros. In this section it was important to type WRL in the avizo title so that Rhinoceros automatically convert a WRL file to a STL file and generate a mesh. It was also important to downgrade this files, because this made the experimenting process more fast. Finally, two downgraded Avizo files, one for the hard material and one for the soft material, and one Rhinoceros shaped model were loaded in Rhinoceros. This is done by the function ‘import’.
The three meshes in a rendered top view.
How to cut out shapes of natural meshes?
This is done with the program Meshmixer from Autodesk. The function Boolean intersection is used in Meshmixer. Meshmixer is used instead of Rhinoceros, because Meshmixer recognizes the patterns as a volume, instead of Rhinoceros. So when two volumes intersect there is created a new closed volume, or a valid mesh/closed double precision polygon mesh. If Rhinoceros does this, there could be a chance that 4 million of triangles need to be flipped by hand and closed again. This would be less secure, and there will be a bigger chance of failure.
Important notice: When the parts were cut out of natural meshes, it was important that the saddle (2 files in this case) was coordinated at the same reference point.
The soft part, created with the function Boolean intersection from Meshmixer.
Finetuning with Netfabb
After creating two shapes, the soft part and hard part, were the shapes controlled by Netfabb. Why Netfabb? Netfabb has a simple repair mode. This repair mode finds holes and repairs them easily and automatic. After this section, there is created a valid mesh, which is also a closed double precision polygon mesh.
The soft part opened in Netfabb, the red sign shows us there is an error.
Creating the product
When the two parts were repaired, they were transferred to Rhinoceros again. And checked if they were both closed and valid meshes. The soft and hard part were seperated and grouped. Now they could be exported both, by export selected, and send as a STL-file to the Connex.
The final product in Rhinoceros, black part is hard, cyan part is soft.