I am following along in the background and starting to get totally confused by the different printers that are needed and various settings - but your image there proves that if people can get their heads round it, wow. What a stunning outcome you have. If I have understood correctly, you have four sleeper blocks linked to gather to create 60-foot length of sleepering? I was in the laser cut timber sleeper camp previously, but the more I see (and the more I hear the minimal cost!) the more I think that 3D printing everything, except the rails, is a good idea.
Superb work Martin - how you get all this to work in the background baffles me! I am assuming a lot is maths and trial/error - but please keep going, you could take on Peco in a few years time!! Within this plug system have you had any thoughts or ideas of how track electric feeds could be hidden - or its that an 'outside the scope of this project' and down to the user to hide them? I am guessing that a light dab with a soldering iron underneath the rail between sleepers wouldn't melt the 3D plastic? then the wire could be 'threaded' down the side of the sleeper and through the baseboard?
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