The interactive guidance enables users to repurpose existing surface mesh models, analyze them in-situ for stress and displacement constraints, add movable joints to increase functionality, and attach a customized appearance. This strategy enables novice users to choose designs that both satisfy stress constraints as well as their personal design intent. Shape Structuralizer embeds a recommendation system that computationally supports the user during design ideation by providing design suggestions on local refinements of the design.

We propose Shape Structuralizer (SS), an interactive design support system that repurposes surface models into structural constructions using rods and custom 3D-printed joints. These programs are free to use.Current Computer-Aided Design (CAD) tools lack proper support for guiding novice users towards designs ready for fabrication. Once unpacked, PDO files can be opened by Pepakura Designer or Pepakura Viewer. The pattern files are packed in a ZIP format. PDF patterns are also supplied if you do not want to install these applications, but the 3d preview helps a ton in assembly.

The 3d models used to make these patterns are created and/or modified by me. If you have a 3D printer, you can download the extra STL models I used for the helmet tube, shoulder ridges and shoulder led strips: I found these were easier to add to the cosplay as a 3D print rather than try to make them in eva foam. If the link doesnt work, go to my facebook page > photos > see all > scroll down until you see ‘samus aran varia suit’ album. If you need help assembling it, check out my Samus Aran Varia suit build album on my facebook. Only one version of each armor piece is added, you can mirror or duplicate patterns to get the other side etc To get the rounding I have in my armor, make sure to ‘make up’ by rounding off the polygonal shapes where needed, and add sharp corners where the Varia suit requires them. You should only cut along the red shell lines. To get the least additional seams possible, merge darts in the patterns together and heatshape where possible. You can emphasize these lines in 3D by lightly dremeling the corners before glueing it together. The patterns seams are aligned with the dark texture lines in the Varia suit reference itself, so minimal seams are achieved.

Pepakura models download