This video documents the process of designing and building a large, illuminated topographic map of the Dirty Devil River canyon for the creator's new workshop. Inspired by a previous laser-cut Grand Canyon map, the project aims to create a 9ft x 10-inch piece. Digital elevation data from USGS is acquired and processed in Blender to generate a 3D model. The creator decides to utilize 3D printing instead of laser cutting for its benefits in build simplification, weight reduction, and detail retention. The design involves splitting the large model into 12 sections for printing. An initial test with pouring epoxy directly into the terrain print for the river fails due to seepage. The design is revised to print the river separately in translucent PETG and glue it to the back. The terrain sections are printed in white PLA with low infill for backlighting. A frame is constructed from 1x4 lumber with a groove for mounting the prints, backed by aluminum sheet metal to act as an LED heat sink. LED strips are installed on the aluminum panel. The prints and river sections are assembled and glued into the frame, resulting in a large, internally lit topographic map.
Creating a Large Illuminated Topographic River Map
0:00 Inspiration & Project Goal: The creator, having previously made a large laser-cut topographic Grand Canyon map, plans to create a similar piece for their new workshop, aiming for a 9ft wide by 10-inch tall illuminated map of a river canyon.
1:01 Location Selection: A search for a long, straight section of river with interesting canyon detail leads to the selection of the Dirty Devil River, a tributary of the Colorado River known for its 20-mile relatively straight path through a 2,000 ft deep canyon.
1:32 Data Acquisition: Digital elevation models (DEMs) for the chosen area are downloaded from the USGS website, requiring multiple files due to the large size.
1:45 3D Modeling in Blender: The DEM data (a black and white image representing elevation) is imported into Blender and used to displace a 2D plane, transforming it into a 3D terrain model matching the map's dimensions. The model is scaled and positioned.
3:01 Manufacturing Decision: The creator decides to 3D print the map using a Bamboo Lab A1 printer instead of laser cutting, citing benefits like simplified assembly, lower weight (using PLA), no need for painting, and better detail retention.
3:27 Model Preparation for Printing: The 3D model is split into 12 sections to fit on the printer bed.
3:58 Epoxy River Test & Failure: An initial test attempting to pour blue epoxy directly into the river channel on a sample print fails. The epoxy puddles and seeps into the PLA print layers, causing splotchy discoloration visible with backlighting.
6:34 Design Revision: The river is redesigned to be cut out of the main terrain print and printed separately as a translucent piece (using PETG) to be glued to the back. This requires extensive manual modeling work in Blender.
7:36 Slicing and Print Settings: The revised 3D models are prepared in Bamboo Studio. The top surface infill is set to concentric to follow terrain contours, and overall infill is lowered to 10% to allow light transmission for backlighting.
8:05 3D Printing Process: Printing of the 12 terrain sections in white PLA takes about a week, with the AMS system facilitating automatic filament switching.
8:50 Frame Construction: A frame is built from 1x4 lumber, left unpainted for a natural wood look. A groove is cut into the frame pieces to receive a matching ridge on the 3D prints, allowing mounting without visible fasteners.
11:03 Aluminum Back Panel: Sheet metal is used for the back panel, providing rigidity and acting as a heat sink for the LEDs.
11:27 Printing and Attaching River Sections: The translucent river sections are printed in blue PETG. These are glued to the back of the corresponding terrain prints using thin flanges on the river pieces.
12:23 LED Installation: Two 25 ft rolls of LED strips are mounted onto the aluminum back panel using their adhesive backs, arranged in five rows. Wires and clips are soldered to connect the strips.
13:24 Testing & Final Assembly: The LED strips are temporarily connected for testing. The 3D printed terrain and river sections are glued into the grooved frame. The aluminum back panel with LEDs is attached to the frame.
15:45 File Availability & Giveaway: The creator plans to make the project files (print files, sheet metal drawings, Blender model) available for purchase and is hosting a giveaway for a small unlit sample piece on Instagram.