A follow-up from the 1st Stellation.

It's a remix of one of the oldest things on Thingiverse, Phooky's 2nd stellation, at thing id 31. This version is an extrusion of those 2D designs (mimicking being CNC cut from 1.8mm sheets), with some parameterization and modifications to make the edges touch up to each other.

Video for demo and assembly.
For guidance on the Blender source file, see the video for the 1st stellation; it covers the source file (for the 1st stellation), and their scene setups are very similar.
https://youtu.be/33G-Onij_zo

Printing

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No supports are needed. Models are already oriented in the correct direction, so the proper side is lying on the bed.

There are 4 different versions; the flush versions are the same, except the slot widths have slight variations to account for different printer behaviors.

• Original
  • Mimics what the output of the original thing would be like. Slots are set exactly to the 1.8mm thickness.
• Flush (Default)
  • A version of the geometry where the slots have been modified so the edges touch.
  • The slot width is modeled at exactly 1.8mm.
• Flush (Tight)
  • A version of the geometry where the slots have been modified so the edges touch.
  • The slot width is a few microns shorter than 1.8mm, providing extra friction and tightening connections.
  • This is used in the demonstration video - printed from a PrusaXL.
• Flush (Loose)
  • A version of the geometry where the slots have been modified so the edges touch.
  • The slot width is a bit wider, giving extra tolerances for printers that print the sheets a bit thick.
  • This is what I needed for tight enough connections when printing from a Prusa Mini+.

Pick one of the versions, print a couple of Triangle models, and one of each Connector model (for that version) and test if the fit when connecting them feels like it slides in well but has a good amount of friction-holding force. If so, print more copies to the correct quantity:

• Triangle
  • x60
• Obtuse Connector
  • x60
• Acute Connector
  • x30

Assembly

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Assembly is more complicated than the 1st stellation but is still straightforward. Refer to the video if needed.

1. In groups of 3 triangles and obtuse connectors, connect the triangles on their shorter sides. Keep in mind the concave part will be the visible part (outward facing).
2. Connect those parts with acute connectors.
   • The acute angles will be facing outwards.
   • The concave region of the combined triangles should point inwards.

When assembling, keep in mind the face lying on the bed will have a different finish than the top side - so it's best to pick which side you prefer and stay consistent with which one faces the outside of the model. This probably makes a good candidate for textured or holographic transfer bedsheets.

Source

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The Blender source file is also included (Blender 4.0). It is parameterized to vary the sheet thickness and slot tolerances.
The parameters can be located as custom properties of the PARAMS object. See their descriptions (which can be accessed as hover-over tooltips) for more details.
See the text document (embedded in the Blender file) for more information and params used for exporting.

Caveats and Disclaimers

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The acute angles are pretty sharp; not a significant hazard, but don't go chunking it at people and take care. The end-assembly is essentially a huge, low-poly, Sweetgum pod.

License

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While the original is in the public domain, this remix is under a CC permissive attribution license.

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