Hi folks. One of the main reasons I purchased a Form 2 was for creating custom toys and models, and probably the thing I do most is design and print custom Lego components. I wasn’t happy with the (lack of) level of detail and the unpredictability of an FDM printer for these pieces, so I invested in the Form 2. I’m quite happy with what I’m able to produce now, however the biggest challenge I have is with supports. Since these blocks need to be able to cleanly interconnect on both top and bottom, I’d ideally not have any supports connect to either the studs on top or the tubes on the bottom side. I’d love to also minimize supports on the face of the blocks but would rather deal with cleaning those up than interfering with the fit.
When I use the One Click mode and let PreForm do its thing, it usually chooses to rotate the bricks on their side and at an angle where the tube is facing downwards. This results in lots of supports on the top studs. But if I rotate the other way so the studs are facing downwards, I end up with resin pooling within the bottom part. I’ve also tried playing with printing these directly on the platform and trying to compensate for the first few layer compression by extending the height in the design, but seems unreliable/unpredictable and impacts fit too much.
Would any of the seasoned experts have any advice on the best way to set these up for supports (while minimizing resin usage)? Also, I’d be interested in hearing if anyone else has tried printing legos or something similar on their Form and what resin they’ve had the most success with. I use the Standard Gray the most, though I find it “gives” or squeezes a quite a bit more than ABS so sometimes pieces can be pushed onto a true lego piece but then “pop” off a few seconds later. In other cases, once it is cured for a while it can crack and be a bit too brittle when pushed onto another brick. White seems to do a bit better. I bought some Gray Pro to experiment with but didn’t realize I needed an LT tank so I’ve got one of those on order.
Here’s an STL of a simple 2x2x2 brick, if anyone would like to play around with it: