3D Printed Clay Geometric Puzzle Modules

Introduction

This project was created by Eva Nie and Liliana Rodriguez as a course assignment at the California State University, Long Beach; taught by Behnaz Farahi: DESN 551: Materials, Tools, and Techniques of Prototype.

In the search for a union between form and function, we've embarked on a journey to create interlocking geometric modules reminiscent of Brutalist architecture. This Instructable will guide you through the creation of these puzzle-like modules, from the digital drafting board to the final 3D printed form using clay.

Concept Story: Echoes of Brutalism

Within the uncompromising strength of Brutalism lies a hidden dialogue between individuality and collectivism. Our design draws from this dialogue, crafting a narrative where each module embodies a raw, unrefined beauty — a single piece of a larger puzzle. In isolation, a module is a testament to minimalist design; when conjoined, they speak to the collective power of a unified structure, echoing the Brutalist ethos where utility becomes art.

• Rhino software for 3D modeling
• Cura for slicing the model
• 3D PotterBot 10 Micro
• Clay for 3D printing

Begin by drafting a basic cross-like shape with protruding ends, ensuring each arm is identical in length and width to enable interlocking. The design is intentionally minimalist, aligning with the Brutalist theme. Once satisfied, extrude the 2D shape into a 3D model and refine the edges for seamless assembly.

Export your design as an STL file and import it into Cura. Configure your settings for clay — adjusting the print speed, layer height, and infill to ensure structural stability. The aim is to print a solid module while considering the drying and shrinking properties of clay.

Please refer to 3DPotter's FAQ section on Cura. The printer we used is the 3D Potter 10 Micro and the Cura settings we used is the Cura Settings (Model 10), WiFi.

Refer to this video tutorial on how to prepare clay for 3D printing and how to load the clay into your printer. One thing to note, you want clay to hydrate for at least 48 hours before you intend to use it for printing.

Set up your PotterBot 10 Micro, load it with your prepared clay, and begin the print. We used 3D Potter's printing software. You'll need to connect to the printer wirelessly through WiFi. Please refer to this video tutorial for a guided walk-through to printing your first design.

Monitor the process closely, as printing with clay can be unpredictable. Be prepared to make adjustments on the fly to maintain the print quality. We found that we had to change the extrusion speed and extrusion amount a few times until we landed on settings that worked best.

After printing, use a spatula to carefully remove any excess clay and smoothen the surfaces. If desired, the modules can be fired in a kiln to solidify their structure and make them more durable. We ended up firing them to fortify them.

The true beauty of these modules lies in their versatility. We imagined using them as decorative art installations or garden structures. For example, with weatherproofing, these modules could be used to create interesting outdoor sculptures or frameworks for climbing plants.