I read an article by Galvin Smith on creating a Dymaxion Globe (Fuller Projection):
Laser Cut Dymaxion Globe
This design was a challenge. I originally downloaded the SVG file from Thingiverse and uploaded it to Ponoko. Only to have them reject it because it didn’t use the correct colors. Updated the colors, resubmit … and … Success! (Laugh) Wait two weeks, get the design back only to find the pucks I had planed on using to hold the map together were too large. (Sad trombone) Updating the map changed it size. I had to design new pucks to fit the smaller design.
Six items are needed to make this design:
A) Laser print the Dymaxion Map (Fuller Projection) at Ponoko:
Dymaxion Map (Fuller Projection) at Ponoko
Note: This is a free design for users to laser cut at their own cost. The design contains two complete maps.
B) 12 pieces of this puck are required for each globe:
Dymaxion Map (Fuller Projection) Puck
C) 60 pieces of “M2X12” screws. The screws shown in the pictures are “M2X12 Phillips Pan Head Machine Screw Stainless Steel A2” type. These can be purchased at hardware stores or online.
D) 60 pieces of “M2X.4” Hex nuts. The hex nuts shown in the picture are “M2X.4 Hex Nut Stainless Steel A2” type. These can also be purchased at hardware stores or online.
E) Small Phillips screwdriver. This can be purchased at hardware stores or online.
F) Lots and lots of patience.
The assembly is difficult due to the small parts and the ever smaller opening to work with as the globe is assembled. I recommend that for the last few panels to be assembled, the user tapes the hex nuts to the bottom of the puck to assist in the final assembly.