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Aztec Scenic Design Creates Custom 3D Printed Arabian-Inspired Ceiling and it’s Amazing!
Aztec Scenic Design, an Orlando-based firm, has successfully integrated 3D printing into its custom ceiling design projects, offering a more efficient alternative to traditional methods. The company recently completed an Arabian-inspired ceiling for a client, demonstrating the potential of additive manufacturing in intricate home decoration.
Traditionally, detailed ceilings can be a significant expense, often exceeding $30,000, due to the labor-intensive process of creating molds and working with plaster. Aztec Scenic Design, however, pioneered a new approach by utilizing 3D printing to produce the decorative appliqués for their custom ceiling. This innovative method was spearheaded by Marc Leonard, a scenic designer at Aztec, who became captivated by 3D printing and sought to merge it with the company's design work. After convincing owner Gabriel Collazo of the technology's potential, Aztec established its own makerspace, specifically for incorporating 3D printing into various applications.
The project began with initial drawings by Benjamin Cremer, based on Arabian patterns. Marc Leonard then translated these sketches into 3D models using 123D Design. Austin K. Butler, a scenic designer and fabricator, joined the team to manage the 3D printing process. The actual printing phase involved several 3D printers, including a Tinkerine Ditto+ and multiple Prusa i3 8-inch printers, and took approximately three weeks to complete. The materials used were around six spools of 3mm ABS filament and three spools of 1.75 PLA filament, costing just over $200, a stark contrast to the potential costs of traditional methods.
The ceiling structure consists of nine wood panels, which serve as the base for the affixed 3D printed components. Gold-leafed molding, cut with a CNC router, frames the design. The 3D printed pieces underwent a multi-step finishing process: painting with acrylics, aging with oil stains, and finally, touch-ups and glazing. The entire installation, measuring approximately 18 feet by 14 feet, was completed in just two days.
One of the most challenging aspects of this project was managing the approximately 400 individual 3D printed parts and troubleshooting five simultaneously operating printers. The team also faced hurdles in working with various software applications, including 123D Design for modeling, MeshMixer for editing, and Slic3r and Repetier Host for slicing. Despite these challenges, the collaborative effort of the entire Aztec crew, including Gabriel Collazo, Marc Leonard, Benjamin Cremer, Janelle Lyons, Timothy Dameron, and a friend named James, proved successful.
This project highlights a significant shift in custom interior design, showcasing how 3D printing can streamline complex processes, reduce material costs, and offer greater design freedom. Aztec Scenic Design's success with this Arabian-inspired ceiling has led to further commissions, including another, more intricate ceiling for the same client's theatre, indicating a growing demand for 3D printed architectural and decorative elements.
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