So, with the change of two parameters, the OpenSCAD program can model a 170×230 mm sheet:
That works out to a 9×13 array of 117 armor buttons sitting amid 140 connecting links, with two threads = 0.8 mm between adjacent links.
It’s quite imposing in black PLA:
The skirt thickness varies from 0.15 mm in the X-Y+ corner to 0.25 mm at X+Y-. That’s so close I’m not even tempted to adjust the screws.
As before, all those links pop off right the cool platform without any fuss; the joints had good clearance, the bridges worked, and nothing required post-processing:
You can’t make this through subtractive machining. You can’t make it using molding, either, because the links have barely a sliver of air on all sides: there’s no room for the mold and no way to extract the sheet of links. You could, I suppose, use lost-wax / lost-plastic casting, but cutting the sprue and vent off every link would get really tedious really fast.
Of course, you’re looking at a 5 MB STL file, 22 MB of G-Code, nine continuous hours of printing, and 120 grams of PLA: it’s the largest “single” object I’ve ever printed…