ChainHex + Scales

Idea

Inspired by NASA Hexagon Chainmail and designed from scratch.

Main issue with existing files was that you needed special pieces to combine sheets together those require glueing and broke easly.

There were several attempts at designing new way of connecting:

Mk1 - Was a failure, not only hard to get printed with all studs in place but also hard to  connect.

Mk2 - That was a step in right direction from Mk1. Printed easier and allowed to connect hex-chains together. Main issue was in movement of chains. Hardly bent into any direction.

Mk3 - Was a failure as well, because connections was not tight enough to keep all hex-chains together.

Mk4 - Succsess! Even though it performance differ with different plastics used, all what I wanted initially was there! Easy to print, easy to assemble, strudy connection between links! After printing some - I had an idea: why not make it look like scales?

Mk5 - Here it is!  Almost same as Mk4 and can be connected with it but with a hexagon hole to attach whatever needed.

As for scale I'll drop most of designs as they were either bad looking, obstruct movement or were hard to get off supports.

Scale Mk8 is latest version as seen on main photo.

Printing

All below was tested on Anycubic Mega S.

ChainHex Mk4 and Mk5

With 0.4 mm nozzle I recomend to print in 0.3 layers with full infill and normal supports. I got better results printing those holes up (see screenshot).

If you print in batches - make sure there are as few as possible movements above supports by turning on combing and rearranging pieces.

Brim or Raft is not recommended as post-processing will be harder.

For the looks - make it all walls (set them to 20+) or/and make concentric layers.

Scale Mk8

Same settings as above with exception of 0.12 layers aand no supports. Lay them on flat part!

For better looks - make z-seam on inner part of hexagon (opposite of scale). 

Materials

Best results were with PLA+ at default temperatures.

Regular PLA had somewhat more failed chains.

Silk PLA had almost 25% of failed hex-chains and 90% of failed scales. While you can get good results with Mk4 hex-chain, I do not recommed it for Mk5 or Scales! 

PETG had good results but it's roughness and stringing resulted in less free moving sheets.

ABS and other plastics were not tested by me yet.