f the mesh was self-intersecting everywhere. So instead I used Millipede (isosurface) to get the same undulations, but ignore the complex 'folds', you can see the difference in cross section thickness. I then tessellated it with the inverse pattern of the outer surface.
To make it a single 3d printable mesh, i just deleted a single face on inner and outer skin, then lofted the naked edges. (creating a tiny hole through the model). Therefore creating a single mesh that folds in on itself, not sure if there is a better way of defining the space between two meshes as the solid area...
Full GH (Kangaroo - Meshmachine - Weaverbird - Millipede)
Special thanks to Laurent Delrieu for his interesting offset mesh method that i based my approach on.
http://www.grasshopper3d.com/forum/topics/offset-mesh-problems-with-3d-mesh-with-weaverbird…
Added by Nick Tyrer at 5:25am on December 10, 2015
Chris,
Again the number of curves which SubCrv gives me is different from the actual curve on the surface! for example it gives me 80 curves in which there are 20 curves!