The missing letters - ‘a’, ‘Z’ & ‘Q’ - need to be recreated. My research uncovered no existing record of these letters meaning that this process requires some detective work. Luckily the Dawson Collection has a similar typeface which is a full solid. I took prints of these letters, then traced these prints using the pen tool in illustrator to get the outline. 

 

For the interior spaces I had to use other existing half solid typeface, and make sure the recreated letters` elements will match other existing letters together: the stroke weight, the solid bottom height, and the little cross area in the letter a. While this took some experimentation, my approximation has a similar feel to the other letters. 

Once I had recreated the missing letter in 2D digital form I imported the Illustrator file into Rhinoceros. I was able to use this software to create a 3D model of the missing type. In rhinoceroses I extruded the 2D vector image of the type into a form that is both the correct height and has a similar profile to the existing type.  To do this I used a digital calliper to measure the height and weight of the real typeface and build the bottom base.To create the correct profile I provided a vertical taper of 15 degrees from the type face down to the shoulder. Once completed, I need to ensure this model has no naked edge,  after this the model is exported as a STL file.

 

This STL file is imported  into Replicator, which is a program that transfers the file into a format that the 3D printer can read, G-Code.  I opted to use PLA to print out the type as it is durable and  extracted from biodegradable materials. In addition to being environmentally friendly, PLA filaments also print in low temperatures. Printing at lower temperatures will greatly reduce the potential for warping on the typeface. This is very important as a flat surface is essential for good print quality. Printing a solid form is very time consuming therefore I opted for a 40% fill.  Even at this setting the total print time took 2 hours to print all three.

By typesetting these printed letters with the original type into words I tested the strength and look of my recreated letters. I found the strength of the printed type to be sufficient to withstand the pressure on the press. The style seemed to blend in with the original type, meaning I got the shapes correct in my 2D design. There is however a texture on the new type that is quite different from the original. This texture is the result of the printing process. Further research may find ways to minimize or correct this texture. Right now I am happy to have the texture as it reminds me of the fact that this is a new version of a traditional process.

FAIL!!!!