After several failed prints and frustrating efforts to clean up the support remnants from the original* in numerous different orientations, I realized it needed very little in the way of support on my printer.
I added supports around the edges, especially for the small, angled "clips" that hold the lights in place, and a central column sized appropriately for a #8-32 hex nut. I used 2" machine screws to hold the corners together. The central column is critical for constructing the icosahedron, as it allows the corners to be loosely placed, then tightened securely after the light panels prevent access to the inside.
Combined with the wire connector, wire socket, and the original apex cap, I was able to hide the controller board inside the complete icosahedron. The power cable fits in the notch between panels where the connectors would go.
* My last attempt at the original is in the upper-right on the cover image (the inside shell was torn up removing the supports).
| aurora_apex_corner_support.scad | 16.8KB | |
| aurora_apex_corner_support.stl | 178.4KB |
