Hi Geertjan,
I understand a shape that will easily be removable from its mold. Which is not a new use for C4D BTW. The STL export is in use for that since long. I provided in ‘99 the first time a file for a “print out”.
Since the 3D printer have become a toy (in terms of affordability) many people use C4D for printing stuff out.
The question is - can you deliver a collage of shapes or has it a “water-tide” single volume?
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The simplest way is to do the preparation in Illustrator. The way I get my different shapes is to make a copy of the path (Spline in C4D) and set a stroke with a certain width over it. Then I outline this and delete the inner liens. This can be done manually or just by placing another copy on top of it, merge both and use the outline from this—after clean up the file, to get only the path I need, then export as v8 and ready to go.
If Illustrator is not available, you can take the spline and copy it. Then use the Mesh>Spline>Create Outline function and create a larger version of the file than before (Mouse down and drag). Then use the Mesh>Spline>Explode Segments and sort the new and the original spline, so you can delete the original shape (copy of course). Now you have the larger version, which looks like the “bold” (in font terms) and the original version. The bold version needs one time: Object Manager>Object>Connect Objects+Delete.
All of that goes then into the Loft [NURBS]. With a huge amount of Attribute Manager>Object>Mesh Subdivision U you should get your desired “local-taper” shape. IF it looks kind of twisted, use the Mesh>Spline>Reverse Sequence on one of the splines, this should do the trick.
If the process allows you might just use the fillets setting for the part that stays invisible in the Base and increase from there, as the top part of any sign should follow the original size. (You mentioned Fillets as a “no” option, but just to mention it.
As I haven’t done it in a while, ask the mold builder f the material needs to have a similar “depth” so the material behaves nicely when heat and expansion comes into the game. Perhaps that is not a concern at all.
All the best
Sassi
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