Using SLS 3D printing, Formlabs created a 3D printed pavilion structure that served as a meeting space at the FUSE 2017 conference.

In order to really test the limits of their new Fuse 1 SLS 3D printer, Formlabs produced a large pavilion structure that served as a meeting space at the company’s 2017 FUSE conference. The event took place on June 6 at the MIT Media Lab.

Amazingly, the final structure is 150 square feet, standing at 15 ft across and 8.5 ft tall. The pavilion for FUSE 2017 is the largest structure, at least that the company knows of, that is 3D printed with Formlabs machines.

The structure is made up of more than a hundred unique construction modules, and can comfortably fit three people inside. These modules took four days to fully assemble.

In order to create the structure, Formlabs explain that they automatically translated an STL file into a structural system. Initially, they thought of creating either a Formlabs logo or a scaled up Stanford bunny. However, they settled on something that has a more functional purpose.

Formlabs explains that they chose a “design derived from the equation for a mobius strip”. The design has an enclosed meeting space and is surrounded by three, sweeping blades that are structurally sound.

3D Printing the Formlabs FUSE 2017 Pavilion

The team used Rhino and Grasshopper scripting to optimize the design for printing. They created 144 3-inch connectors from Nylon 12 for the pavilion, printing them in a single build. In order to make sure they all fit together, they optimized the placement of the parts. All in all, it took 36 hours of printing on the Formlabs Fuse 1 3D printer.

This is possible because SLS 3D printing technology doesn’t require supports, therefore hundreds of unique parts can be printed at once. Formlabs adds: “We hope our pavilion connectors represent the future possibilities of mass custom manufacturing, where each part can respond to unique and individual needs.”

Next, for the struts, the team used hollow fiberglass tubing. Interestingly, the HDPE laser-cut panels are the heaviest component. However, before these 100 lb panels were added, a single person could lift the pavilion.

Lastly, the team printed their hanging hardware using their famed stereolithography (SLA) 3D printing and Durable Resin material. After that, it was finally time to assemble the structure.

The Formlabs team explains that assembly was the hardest part of creating this large modular structure. In fact, three people spent six hours a day for four days working on the pavilion’s construction. This is essentially the ultimate jigsaw puzzle.

The final design certainly looks very impressive and is probably a great place for a small and intimate meeting. If you want to find out more about the build, visit the Formlabs website where they have detailed the process. You can also learn more about the Fuse 1 3D printer on All3DP.