Summary

Attempting to make a keychain that is truly 3 dimensional. I have created this frame using OpenScad and linear extruded the helix shape. However, I am having trouble printing this frame.

If I turn supports on, an extruded triangle is created as the supports create a wall to support the upper tier as well as within the columns.

Without supports, only the bottom triangle can be partially printed.
A little help here, please?

Print Settings

Printer Brand:

MakerBot

                                            <p class="detail-setting printer"><strong>Printer: </strong>                     <div><p>MakerBot Replicator (5th Generation)</p></div></p>                                                                                <p class="detail-setting rafts"><strong>Rafts: </strong>                     <div><p>Yes</p></div></p>                                                                                <p class="detail-setting supports"><strong>Supports: </strong>                     <div><p>Doesn't Matter</p></div></p>                                                                                <p class="detail-setting resolution"><strong>Resolution: </strong>                     <div><p>0.2 mm</p></div></p>                                                                                <p class="detail-setting infill"><strong>Infill: </strong>                     <div><p>10%</p></div></p>                                                        <br>                        <p class="detail-setting notes"><strong>Notes: </strong>                    </p><div><p>Supports on becomes too dense.<br>Supports off becomes too fragile. </p></div>

Post-Printing

Too Much Support Material

            <div><p>I don't mind printing with supports but I am having trouble cutting away (heated x-acto knife) the support material without cutting into the actual print. Any suggestions?</p></div>

How I Designed This

OpenScad, Isosceles Triangles and Trig

            <div><p>I created a sphere and then three linear extruded circles of a certain height and twist.<br>Each circle was placed as a vortex on an isosceles triangle and extruded. </p><p>This sphere and helix design was modularized and then each module was translated and rotated to create the frame of an isosceles triangle and columns.</p><p>while the first vortex was at 0,0 and the second vortex was at (length, 0) the third vortex was found using trig, the 60 degree angle, and the length.</p></div>

Triangle_Helix_Frame