After further testing I have discovered that for the time being, a hexagonal grid pattern is not a viable solution for this semester’s research with the limited time left.
Due to the fact that the plastic is not directly smashed on the the fabric as it was during the 2D panel tests, there is a little bit of drag that is allowed before the plastic hits the suspended fabric—this causes a certain amount of curve smoothing to occur in the the extrusion path. Therefore a diagrid pattern is still the best solutions as it allows the extrusion path to be linear allowing the plastic to settle onto the fabric according to the pattern.
(See other posts for the python scripts used to generate this pattern)
Other issues have been discovered while testing the potential of using the extruded plastic as structure as well. There is a certain amount of warping that occurs due to the plastic cooling as it is printed. This could simply be solved by printing on a heated table. Again, however, due to time constrains with the end of the semester closing in, I have been forced to resort to an alternative solution. I will simply CNC route the structure from 1/2 in MDF.