Skeinforge wasn\'t happy with the last version of the Hexagonal Box, and after some discussion on the Thingiverse Google Group (recommended reading, by the way), Zach pointed out that non-manifold vertices were a possible culprit.

Well, turns out he was right! I went back to Sketchup, eliminated all the points in the model where two pieces of the model touched along a single edge, ran it thru MeshLab to check for mesh defects and export to STL, scaled the STL in Blender, and then ran SkeinForge on the STL file... getting a beautiful toolpath.

Thanks to everyone on the Group for the suggestions/tips/tricks!

http://groups.google.com/group/thingiverse

With Skeinforge happy with the STL file, and the toolpath visualization showing decent detail on the lock tabs, the only thing left is to print one out for final validation!

According to Skeinforge, it should take a little less than 17,000 seconds and 31cc of material to make this Thing. Call it 4 hours and 45 minutes. :-D

As with previous versions, six of these should lock together to make a box, and it\'s recommended to assemble two (three section) halves and mate those last.