This is a re-design of my tesselating flower coaster. Whilst I had originally been happy to use filament swap as a means to change colours, I found this method to be unpredictable when changing from PLA to ABS (the ABS petals ocassionally failing to adhere) and the flowers are limited to one colour only. A re-think was in order and I decided an inlay method would be the best way to go. Not only would it give me the freedom to have as many different coloured petals as I would like, there was the challenge of creating two models which must fit together and appear seamless.
I used this software to design the tessellation with:
Print the petals with a heat reactive ABS filament for a striking effect.
You will need both files to make these. You will need to print 78 petals for each coaster.
I printed my coaster base with a 35% infill with the top and bottom 3 layers as solid. Each coaster holds 78 petals and I printed mine with a 100% infill. Whilst the petal has been sized to fit the holes, given the variation of plastics available it is absolutely necessary that you carefully measure and set up a profile in your slicer for each plastic using calipers to ensure you have a good average of the filament diameter. If you don't you are likely to end up with under or over extrusion and a bad fit.
I found a file was useful to smooth out any uneven edges and that the petals are best secured using a model glue or super glue.
If you want to stand hot drinks on the coaster, the flowers must be printed in ABS. The petals are designed to sit proud of the base and take the heat. Of course, if you print your entire coaster from ABS this won't be an issue, but I wanted to mix the filament types and it was important that the design be able to protect a base printed with PLA. If you want to use the coaster on any surface considered delicate, then I recommend you attach an additional base to it and test first. I also suggest you test how well your filament of choice can handle heat.
British techie (now 3D artist and designer) living in Texas since 2013. Owner of various open source printers. Love of assemblies, automata and support free models.