Lately I have tried to build some of the 3D models based on 2D printouts. Of course it is possible to put the models out in the STL format and send them over to the folks at CAD span. But the price tag is still a bit heavy. As I am on a low budget, I found it therefor more helpful to make the models in 3D on my computer and then project them piece by piece onto a 2D format. On a small scale base, they then can be printed out on a ordinary printer before being glued and put together in its ordinary 3D shape. The process is fast and easy and reliable for the small scale models. The 1:1 scale is a challenge. The printing can be done using a software like Posterize. This handy software let you print out images in any dimension. I tried up to 60 pages to get the full scale model. This was then transfered to cheep aluminum or other materials to get the reflector designed. The challenges that arises are linked to the functionality of the models. I found that even though it works well on a small paper based model, full scale models with other material, gave me quite a different picture. My software does not allow me to test out or analyze the functionality, it just gives the geometry. The geometry can look nice but it should not be a big surprise to anyone that reality always is more complex than our designed models! They often gives me small surprises based on details that gets bigger in a full scale focus, or the way material change based on the dimension being used. Bigger models demand another level of support and structure than small models.
Still by making the models as accurate as possible in the design process, and then making some small models, a lot of problems can be found and corrected before going full scale.
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