Issues merging meshes into single watertight elements for 3D printing

Grasshopper
1

Hi everyone,

I’m working in Grasshopper/Rhino on a modular system for a 3D printing project, where I want to divide a geometry into 12 modules and generate tabs/slots for assembly between parts.

What I’m trying to achieve is to split a geometry into modules, generate connection tabs along the shared edges, and then merge each tab with its corresponding module so that each module becomes a single, clean, watertight element ready for 3D printing.

The main issue I’m facing is reliably joining the tabs to the modules while maintaining clean closed mesh. I’m struggling to get everything to merge properly without gaps, overlaps, or broken boundaries, and to ensure the final output is valid for 3D printing.

In the Grasshopper file, I already have 4 pieces assembled.

Any advice on a robust workflow for achieving this, either in Rhino or Grasshopper, would be greatly appreciated.

Thanks.

MESH_MODULES.gh (13.2 MB)

2

Perhaps not the answer you are looking for, but your slicer software should be able to do this as a one-off mesh chopping.

Unless you are looking for repeatability of the process or a bespoke joint design?

For example you can do a dovetail joint w/ Bambu lab:

Cut Tool | Bambu Lab Wiki