Omnipanels - Square (Old)

NOTE: These are the old Omnipanel squares, I have published an updated system.

Similar to the well known Polypanels by Devin Montes, this is the start of a new panel system I am designing (again). I have changed the panels to a new improved design. While most of the images are of the old panels, they are functionally identical to the new ones.

These are just the base panels of the system, and I will publish many more features and capabilities for moving parts, gears, etc. in future such as the beam engine model I made for the original prototype system I designed for Polypanels (click to see the moving GIF):

Follow me to be updated when I publish new parts (soon™).

UPDATE 17/05/23: I have added the FreeCAD file for the base A panel.

How the Omnipanels System Works

The system is composed of squares with standard and internal connectors: 

Standard Connector:

Internal Connector:

The connectors work as follows: 

• A standard connector can join to any other standard connector, except when one of them is flipped.
• A standard connector can join to any internal connector, except when one of them is flipped.
• An internal connector cannot join to another internal connector, only to standard connectors.

The connectors are designed, such that four connectors can join at an edge (two standard and two internal):

This allows you to build square grid structures of any shape and size.

Building a grid structure

To build a grid structure with 'A' panels, you need to follow two simple rules:

1. When joining two panels in line, use the same connector type and orientation.

2. When joining two panels at right angles, use different connector types.

These simple rules produce the ‘A Panel Pattern’ which you can see above. Since each joint is at right angles, they all have different connectors joining on each side. This may sound complex at first, but when you get your hands on it, it's pretty easy.

This pattern can be continued to produce a cube:

The white lines have been added to show the orientation of the panel. This pattern can be continued to a larger structure:

Which can then be covered in more panels:

This grid structure can be continued indefinitely to any shape or size. As long as the two rules are followed, there will be no collision or interference at any joint. 

Due to the nature of Omnipanels, sometimes not all connectors at an edge will be joined together e.g. at the edges with 2 internal connectors and one standard connector, one of the internal connectors will be loose. To rectify this we can add ‘Stitches’:

Stitches

‘Stitches’ are essentially loose standard connectors. By adding a stitch to the structure above, we are essentially creating 4-way joints, making them fully rigid. Whenever there is a joint with loose connectors, add one or two stitches to make it rigid (or you can use reinforcing clips).

B  Panels

You can build any rigid structure with just ‘A’ Panels and stitches if you want, but there is another way to build with different panel types: 

Here we have replaced the surface panels of the grid structure with ‘B’ panels. These panels swap one of the internal connectors with a standard connector. Essentially, the B panel provides an extra standard connector at a joint, instead of adding one with a ‘stitch’, although this requires breaking the standard ‘A’ panel building pattern. 

Simply by covering a grid structure with ‘B’ panels, this is another way to make it fully rigid (although you will find some surface panels may still need to be ‘A’ panels).

We can go a step further by adding some ‘C’ panels:

C  Panels

‘C’ panels have just standard connectors and no internal connectors. By placing them in specific locations we can make each joint have two standard connectors. This is also fully rigid, but the standard connectors make for stronger joints, and a stronger overall structure.

‘C’ panels are essentially the same as the original Polypanels, but in this system they are used for selective reinforcement, or for the surface of hollow structures.

D, E  and F Panels

As you get more proficient with building, you can break the standard pattern and go into more freeform building. You should only need the 'A', 'B' and 'C' panels but I have included 'D','E' and 'F' panels variations to cover all possible panel types if you need them.

There are also solid panels, which fill the open centre of the squares, although use a little more material:

Below are some examples of larger structures using Omnipanels (including some half panels which have not been published yet):

The STL files have small brim areas pre attached to the connectors to aid with bed adhesion. These can simply be pulled off with your fingernails or some snips.

Panel Joining

When joining a panel into an internal corner, there is a best procedure to follow so it goes in easily. You should join the standard connector first, while the internal connector fits into a small clearance gap: 

Then rotate the internal connector into place and join along the second edge.

Panel Tool

I have also included a panel tool, to more easily lever the panels apart. It is best to start at the weakest joint and move around the panel (and the reverse while assembling). The grooved side of the tool helps save your fingers when joining lots of panels together.

This concludes the intoduction to Omnipanels. These are just the base panels of the system, and I will be adding many features and capabilities for moving parts, gears, etc. in future such as the original prototype system I designed for Polypanels:

Stay tuned…