How can I make honeycomb ribs in the bottom of this tray?

Hello all.

This tray is going to be an injection moulded piece made out of recycled ABS. I would like to add honeycomb style ribbing at the bottom.

I have already tried drawing lots of polygon shapes as seen in the image however for some reason those shapes are unable to be joined together into one. I selected them all and used the rib command, adding a draft angle of 1 degree but this results in a mess - some of the hexagons don’t become ribs at all and others become misshapen.

How else could I make these honeycomb ribs with a draft angle?

Thanks in advance!

Hi James - I think I’d make one unit and array/copy it around to make the whole field

-Pascal

Hello Pascal. Many thanks for taking the time to respond. Did you draw the hexagon then use the rib command, followed by array/copy? @pascal

Hi James - I’m sure there are different ways of getting there - I made two hexagons for the base and two for the top. I lofted these using ‘Straight sections’ in the Loft command. I capped, then made a polar array,of six around the original, with the top faces completely overlapping. BooleanUnion followed by MergeAllCoplanarFaces.

Then I trimmed out one unit using the larger hexagon aligned to the mid points of the radialy oriented sides.

@James_Lee - saved as V6 here -
HexArray.3dm (2.1 MB)

-Pascal

Sorry for the late reply. When I try to loft the drawn hexagons there is always a gap left and when I cap it, it caps the space in the middle rather than the empty space on the side. I re-lofted the outer-most hexagons and boolean unioned them together so it became a solid. My other issue is the polar array, I cannot get it to all 6 points. Please could you help me with this? Many thanks for your help.
(I am using Rhino6 so was unable to open the Rhino doc you shared) @pascal