How to Create “Miniature Infrastructure” with 3D Printing?

3D printing technology has entered campuses, serving classroom teaching, competition projects, and innovative experiments. In schools of architecture, the applications of 3D printing go far beyond expectations.

Note: The following application-related images and textual materials are sourced from Russell Zeng of the College of Architecture, Art, and Planning at Cornell University (罗素小儿@Xiaohongshu).

01 TPU-95A Cement Casting Molds

Traditional casting molds are typically made of silicone, which offers advantages such as high flexibility, suitability for complex geometries, high demolding efficiency, and reusability. As 3D printing technology becomes increasingly integrated into production and daily life, students are also exploring how to improve learning efficiency through 3D printing. The application of TPU cement casting molds is a relatively successful example.

Focusing on user experience and understanding the stories behind 3D printing, we also had a brief conversation with this “architectural model expert” regarding this application.

ESUN: When producing architectural models, what traditional methods are commonly used?

Russell Zeng: Foam board cutting, laser cutting, CNC machining, or manual mold replication.

ESUN: Based on practical experience, what are the characteristics of these methods compared with 3D printing?

Russell Zeng: Model making generally adopts different methods depending on requirements. These methods can achieve many things, but once the geometry becomes slightly more complex—such as curved surfaces, openings, or continuous forms commonly used by architecture students—the cost of traditional methods becomes very high and labor-intensive. The biggest advantages of 3D printing are efficiency and freedom. It can basically realize all kinds of complex structures, and repeated modifications are not a concern, which is particularly important in model making.

ESUN: 3D printing indeed shows significant advantages in designing and producing complex curved and irregular structures. This time, we mainly used 3D printing for cement and plaster casting molds. Do you have any experience to share?

Russell Zeng: It is mainly about material selection. We highly recommend using TPU-95A material for cement casting molds. Demolding is extremely easy. TPU-95A has just the right hardness, and its flexibility is very suitable for casting and demolding. The surface details of the printed models are also very stable, and the accuracy fully meets requirements. Most importantly, demolding is very smooth, with no edge-biting issues, and the molds can even be reused.

ESUN: TPU series flexible materials indeed have very broad application scenarios. Have you encountered any issues during use?

Russell Zeng: They are basically common issues associated with flexible material printing, such as difficulty in removing supports, limitations when printing large sizes, and slightly reduced stability during high-speed printing.

ESUN: Besides TPU materials, what other materials can also be used for casting molds?

Russell Zeng: In the early stages, we also conducted some structural tests using PLA and PETG. When using PLA to make molds for complex shapes, demolding requires more caution, and a hot air gun may be needed if necessary. Overall, for casting molds, we still recommend using TPU materials, as flexibility is critical.

02 Architectural Model Validation

3D printing technology also demonstrates significant advantages in producing complex curved and irregular structures. A wide range of 3D printing materials can meet different application needs. For example, transparent materials are well suited for architectural transparent components, while biomimetic materials such as wood and marble can be used to simulate real architectural effects. Overall, through 3D printing, students can better express the design process and quickly validate ideas.

Enhancing understanding through communication. If you have any opinions or suggestions regarding 3D printing material products, you are welcome to contact us and provide feedback.

ESUN: As a user, based on practical applications, do you have any opinions or suggestions regarding eSUN materials?

Russell Zeng: We have used a lot of eSUN materials this year, and the feedback has been very positive. Our entire grade is basically using eSUN materials now, and we are also grateful for eSUN’s support. In terms of suggestions, based on my own usage habits, I hope flexible materials can offer more subdivided hardness levels and color options, such as more transparent TPU or matte TPU, which would be very popular in architectural models.

ESUN: To be candid, more flexible material color options and a more comprehensive flexible material matrix are currently under continuous development and improvement. We look forward to it.

eSUN continues to support the application of 3D printing across various industries and provides free material sponsorship, printing techniques, and experience sharing for education, teaching, competitions, and scientific research projects. By encouraging innovative practice, eSUN contributes to talent development. If you are currently conducting or planning related projects and are willing to share 3D printing application stories or experiences, please feel free to leave a message and contact us.