To fabricate the model to the level of detail needed the group chose to use rapid prototyping. Using rapid prototyping allowed for us to make quick revisions and produce parts on a much cheaper scale than other forms of prototype manufacturing.

Understanding how 3d printers work is crucial to the group being able to feel comfortable in leaving a part to print for 10-12 hours and not having to worry if the part will fail. This was done by first ensuring the machines were calibrated correctly by using a standard 1 cm x 1 cm cube and measuring after it prints. The group then printing a variety of different objects in order to understand how 3d printers work.

The group discovered that by using a method of hexagonal slicing to create the internal geometry a partially hollow center known as infill was created. Using an infill allowed the part to be sturdy, lightweight, and print relatively quickly.

One of the biggest problems we discovered through testing and playing with printed parts is that the parts need to be printed in a way that allows for the forces to be subjected to the material in the direction axial or parallel to the layers as the separation between layers is the most vulnerable to breaking. As can be seen in the CAD files (located in the files section) and picture below, the group created tensile and compressive test samples in order to help understand the material properties of 3D printed parts.