This "foil" structure is the central piece of one of my latest hobby projects but I have no way to manufacture that structure. I've considered making square pillars which could be produced with a diy wafer saw for which at least the spindle motor exists... see where this is going, recursive problems |O
The aspect ratio is key here, if the structure turns out to be too high res (0.2mm pillars, each 1.0mm high, 0.07mm gaps in between them) the model can be tweaked.
I've attached the initial test .stl which covers an area of 20x20 mm²
OpenSCAD code:module hexagonal_prism(r,h){
polyhedron(
points=[
[r,0,0],
[ 0.5*r, 0.5*sqrt(3)*r,0],
[-0.5*r, 0.5*sqrt(3)*r,0],
[-r,0,0],
[-0.5*r,-0.5*sqrt(3)*r,0],
[ 0.5*r,-0.5*sqrt(3)*r,0],
[r,0,h],
[ 0.5*r, 0.5*sqrt(3)*r,h],
[-0.5*r, 0.5*sqrt(3)*r,h],
[-r,0,h],
[-0.5*r,-0.5*sqrt(3)*r,h],
[ 0.5*r,-0.5*sqrt(3)*r,h]],
faces=[[5,4,3,2,1,0],[6,7,8,9,10,11],
[0,1,7,6],[1,2,8,7],[2,3,9,8],[3,4,10,9],
[4,5,11,10],[5,0,6,11]]
);
}
pillar_radius=0.1;
gap = 0.07;
pitch = 3*pillar_radius+2*gap/cos(PI/3);
pillar_height = 1;
base_height = 0.5;
union(){
for(y=[-30:1:30]){
for(x=[-18:1:18]){
translate([x*pitch,(2*y )*pitch/3*sqrt(3)/2,0]){
hexagonal_prism(pillar_radius,pillar_height);
//hexagonal_prism(pitch*0.25*sqrt(2),-base_height);
};
translate([(x+0.5)*pitch,(2*y+1)*pitch/3*sqrt(3)/2,0]){
hexagonal_prism(pillar_radius,pillar_height);
//hexagonal_prism(pitch*0.25*sqrt(2),-base_height);
};
}
}
translate([-10,-10,-base_height]) cube([20,20,base_height]);
}